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May 16th, 2008, 12:36 AM   #1
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Fork seals

My fork seals are shot at and i would like to change them myself, dose anyone know where i can get a manual to help as i have never do any work on forks before. Or should i just bite the bullet and hand over the chash and let some one else do it.
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May 16th, 2008, 11:16 AM   #2
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RE: Fork seals

read the doc and come back here with questions. if you feel you could service the bike then you're about ready to do your first set of forks.

you need to untighten (not take out) the compression bolts underneath the legs as well as the caps at the top. then remove the forks.

take off the cap and pull the spring which will drip. turn USD and pour out the oil. hydraulic it to get it all out. then undo the compression nut underneath and again oil will dribble.

dust cap up and off
look for an internal circlip next and have that out using a dentists pick
now the unbelievable bit. you have to pretend you have a xmas cracker snd by holding an end in each hand you to pull, pull and pull in three jolts and they will come apart.

you will record their order on paper or look at the photo in the doc. i still forget sometimes.
abrasion ring
dust seal
circlip
fork seal
steel washer/ring
fork bush
fork bush still in the inner leg

now i'll go look at the doc and test myself!!!!!

you may want to undo the nuts that hold all the shims and check them over.

when rebuilding you just reverse it all and have to measure the oil you put in.

regards

Taffy
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May 16th, 2008, 11:40 AM   #3
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White Power 4357/4860 pdf. and special tools.
Attached Files
File Type: pdf KTM special suspension tools PDF.pdf (1.21 MB, 130 views)
File Type: pdf White Power 4357 and 4860 MX Multi Adjuster.pdf (1.63 MB, 112 views)
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May 16th, 2008, 12:31 PM   #4
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try and get the top one into the doc.

thanks eric.

regards

Taffy
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May 16th, 2008, 04:04 PM   #5
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You should give it a go. It's not a tough job, easier than the Kayaba forks on my 'ole YZ250F, IMO. I did find that heating up the end of the outer fork tube like the manual says helps to keeps the support ring from getting dished. When you put the support ring in, use it to seat the bushings before seating the oil seal. Also, when seating in the new seal you don't have to beat the snot outta' them to get them to seat! I pressed mine in then tapped a few times to make sure they are past the circlip groove. Read the fork section in the DOC, and download the WP manual; read them both a few times before you start.

Jason
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May 16th, 2008, 05:04 PM   #6
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Originally Posted by Taffy
try and get the top one into the doc.

thanks eric.

regards

Taffy
Hopefully json will add both to the downloads section and the doc can reference a link. I already uploaded them to the site. The KTM Special Tools pdf. was a nice find.
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