KTM 990S fork seal replacement

[Paulsky]

On our Willehond toer one of my forks started to weep oil a little, so I replaced the seal and dust wipers tonite and here's a little RR on it

first take the forks off of the bike

<a href="https://picasaweb.google.com/lh/photo/L28b33S1n4Dw32uZ-Vkh_g?feat=embedwebsite"><img src="https://lh3.ggpht.com/_JrBBbunwylA/THbA5K9okII/AAAAAAAALAg/K8sPckAD-CA/s800/Cell%20pics216.jpg" /></a>

To open the tops you'll need a KTM special tool available from KTM, it has four little pins which locate and loosen the cap

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The other special tool you will need is a 22mm spanner that you have to take an angle grinder to to make it thin enough to fit in a slotted aluminuim nut, a normal size spanner will not fit

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Take a 24mm socket and put it on the top preload adjuster nut and loosen holding the 22mm at the same time

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Take the springs out and I always take out the rebound damper rod out and put it on the bench, it can slide out whilst working on the forks and get bent

Pour out the oil and dispose of it

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Next prise out the wipers gently with a fat screwdriver, it doesn't matter if you fuck them up we're going to replace them anyway

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Inside the tube you'll find a circlip which again with a flat screwdriver comes out easily

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Once that is out just pull the forks apart

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Than slide everything off of the shaft and place it in the order that it came off on the bench

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I always wrap the end of the slider with a little clingwrap and then push on the new dust wiper and seal on, it protects the seal lip

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Put the bearings and clips back on and slide everything back together being sure that the circlip seats nice and snug

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yet another special built with an animal syringe from BKB and and brass tubing from your local hobby shop

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Fill the forks with 5 weight oil before you put the springs back compressed all the way down and use the syring to suck out oil to a depth of 100mm

<a href="https://picasaweb.google.com/lh/photo/8cNdQdnpDC3WKgmKsm5TPg?feat=embedwebsite"><img src="https://lh6.ggpht.com/_JrBBbunwylA/THbBBtsteqI/AAAAAAAALBI/I6X3aZvsgdQ/s800/Cell%20pics221.jpg" /></a>

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Re-assemble everything, put the forks back on the bike and go riding.

 

[Chuck U Farley]

 

[Sprocketbek]

 

[Paulsky]

 

[funacide]