WP48 - Changing Fork Seals

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by McVick, Dec 12, 2011.

  1. McVick

    McVick Been here awhile

    Joined:
    May 12, 2009
    Oddometer:
    234
    Location:
    Central Arizona
    Hi,

    My 2005 KTM 950 AdventureS is one more project away from being reconditioned after sitting for a bit.

    Now I am on to tackling a fork seal change on the bikes WP48 forks with Synergy Seals.

    I have run into a bit of a holdup however, the 22mm groove just under the cap is tough to work.

    All of the 22mm wrenches or ajustable wrenches I have are too thick to fit into the groove. The 22mm groove you see when you pull the spring down away from the cap.

    I have sourced a low profile 22mm cone wrench made by Park Tools at one of the local bicycle shops and will pick it up today.

    Has anyone else figured out another solution?

    Thanks
    Brian
    #1
  2. rider914

    rider914 Agnostic Adventurer

    Joined:
    Feb 28, 2005
    Oddometer:
    2,535
    Location:
    Alta Loma, CA
    In my box of miscellaneous tools, I found a 7/8" (close enough to 22mm) wrench stamped out of ~1/8" plate. This was probably one of those cheap wrenches that comes with a circular saw, angle grinder, or air tool (used for changing a blade, disc, or whatever). Works great.

    BTW, I tried synergy seals once on my 950. A beeyoch to install and still a ton of stiction after ~1000 miles. I tossed 'em and went back to stock.

    -M
    #2
  3. 1fsttrk

    1fsttrk Adventurer

    Joined:
    Sep 29, 2005
    Oddometer:
    17
    Snap-On has a "low torque" very thin wrench that works perfect for this. It wasn't super cheap, but gets the job done.
    #3
  4. KTMSER

    KTMSER Big bike friendly

    Joined:
    Nov 7, 2006
    Oddometer:
    2,760
    Location:
    Six feet from hell Phoenix AZ
    Grind one down to fit...

    Those seals suck, use OEM or the new SKF...
    #4
  5. Weldit

    Weldit Been here awhile

    Joined:
    Nov 4, 2009
    Oddometer:
    336
    Location:
    Muskoka Ontario Canada
    #5
  6. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,864
    Location:
    Turning expensive metal into scrap
    I ground a wrench to fit
    #6
  7. Konflict Motorsports

    Konflict Motorsports KM TUNER

    Joined:
    Dec 30, 2009
    Oddometer:
    908
    Location:
    Redmond, Wa-Thousand Oaks Ca.
    Sears offers tappet wrenches which have a very slim design, snap on and Marco as well do. I would recommend to upgrade the bushings while your in there. Those year forks have terrible strict ion issues, better quality seals, upgrading the bushings, and polishing the lowers works wonders.
    #7
  8. crofrog

    crofrog Long timer

    Joined:
    Sep 26, 2007
    Oddometer:
    1,455
    Location:
    Annapolis Maryland
    I'd consider getting the updated SKF seals and bearings instead of the synergy's personally.
    #8
  9. Konflict Motorsports

    Konflict Motorsports KM TUNER

    Joined:
    Dec 30, 2009
    Oddometer:
    908
    Location:
    Redmond, Wa-Thousand Oaks Ca.
    +1
    #9
  10. McVick

    McVick Been here awhile

    Joined:
    May 12, 2009
    Oddometer:
    234
    Location:
    Central Arizona
    The tappet wrenches would have been nice. I see them on the Sears site now, unfortunately when I was in Sears last weekend the tool guy never mentioned them even when I told him I needed a thin wrench.

    The Park Tool cone wrench from the local bike shop will work perfectly though.

    I just bought the new Synergy Seals, after hearing lots of great things about them. At this point I'm gong to use what I have. I also have new bushings to install.

    Hopefully tonight will allow for some time to complete the project!

    Brian
    #10
  11. Off Road Ryder

    Off Road Ryder Long timer

    Joined:
    Mar 29, 2010
    Oddometer:
    2,895
    Location:
    Kent Wa
    Looking at doing the same thing very soon.
    Anyone have the SKF seal and bearing part #s??
    #11
  12. fast4d

    fast4d Long timer

    Joined:
    Jul 27, 2007
    Oddometer:
    2,529
    Location:
    Los Angeles, CA
    I bought a cheap 22 combo from harbor freight and grounded it down.
    #12
  13. Konflict Motorsports

    Konflict Motorsports KM TUNER

    Joined:
    Dec 30, 2009
    Oddometer:
    908
    Location:
    Redmond, Wa-Thousand Oaks Ca.
    I carry the SKF's in stock, as well as the updated bushings. I need to get in contact with the guys at Cyclops anyways...
    #13
  14. Peanuts

    Peanuts Long timer

    Joined:
    Sep 12, 2009
    Oddometer:
    1,764
    Location:
    Beautiful but often rainy North Yorkshire, UK
    <TABLE style="WIDTH: 284pt; BORDER-COLLAPSE: collapse" border=0 cellSpacing=0 cellPadding=0 width=379><COLGROUP><COL style="WIDTH: 96pt; mso-width-source: userset; mso-width-alt: 4681" width=128><COL style="WIDTH: 188pt; mso-width-source: userset; mso-width-alt: 9179" width=251><TBODY><TR style="HEIGHT: 12.75pt" height=17><TD style="BORDER-BOTTOM: #f0f0f0; BORDER-LEFT: #f0f0f0; BACKGROUND-COLOR: transparent; WIDTH: 96pt; HEIGHT: 12.75pt; BORDER-TOP: #f0f0f0; BORDER-RIGHT: #f0f0f0" class=xl63 height=17 width=128>48600968</TD><TD style="BORDER-BOTTOM: #f0f0f0; BORDER-LEFT: #f0f0f0; BACKGROUND-COLOR: transparent; WIDTH: 188pt; BORDER-TOP: #f0f0f0; BORDER-RIGHT: #f0f0f0" width=251>DUST SEAL DL D48 SKF</TD></TR><TR style="HEIGHT: 12.75pt" height=17><TD style="BORDER-BOTTOM: #f0f0f0; BORDER-LEFT: #f0f0f0; BACKGROUND-COLOR: transparent; HEIGHT: 12.75pt; BORDER-TOP: #f0f0f0; BORDER-RIGHT: #f0f0f0" class=xl63 height=17>48600969</TD><TD style="BORDER-BOTTOM: #f0f0f0; BORDER-LEFT: #f0f0f0; BACKGROUND-COLOR: transparent; BORDER-TOP: #f0f0f0; BORDER-RIGHT: #f0f0f0">OIL SEAL RING D45 SKF</TD></TR></TBODY></TABLE>
    #14
  15. Off Road Ryder

    Off Road Ryder Long timer

    Joined:
    Mar 29, 2010
    Oddometer:
    2,895
    Location:
    Kent Wa
    Looks like you just got a new customer, Although I like doing my own work, sometimes its worth having the pros do it..

    Thanks
    #15
  16. Johnf3

    Johnf3 Long timer

    Joined:
    Apr 10, 2007
    Oddometer:
    1,072
    Location:
    West Texas
    Looks like Konflict has it covered. KTM also sells the SKF seals and bushings in an upgrade kit--all the 2012 KTM bikes come with the SKF parts stock. This is a nice upgrade if you need seals or are rebuilding your forks.
    #16
  17. Zuber

    Zuber Zoob

    Joined:
    Sep 28, 2004
    Oddometer:
    2,217
    Location:
    Main Street, Shedd, Oregon
    Replace both the seal and the dust seals (scrapers). The scrapers are your first defense.

    The stock seals come from NOK, you can find the seals/scraper set from most M/C warehouses, like WPS, Part Unlimited, or Tucker Rocky. The Pro-X brand seals are really NOK. Set usually goes for $45.

    Use the Maxima Racing fork oil also, it is very slick and will reduce stiction.
    #17
  18. slackmeyer

    slackmeyer Don't mean sheeit. .

    Joined:
    Jul 23, 2007
    Oddometer:
    3,215
    Location:
    Berzerkeley, CA
    :puke1
    Gotta disagree with that. I put in maxima, and took it out a few days later, put in Redline. Maxima does have low stiction, that's because it is low viscosity for the stated weight, and it gets thinner quickly as it warms up.

    But hey, if it works with your valving, great. Didn't work for me.
    #18
  19. UngaWunga

    UngaWunga Mosquito bait

    Joined:
    Jan 7, 2005
    Oddometer:
    8,088
    Location:
    NH
    Is there a part number for the KTM updated kit (oil seal, dust seal, fork bushing)?
    #19
  20. McVick

    McVick Been here awhile

    Joined:
    May 12, 2009
    Oddometer:
    234
    Location:
    Central Arizona
    Ok,
    How about the oil level?

    WP manual says 25mm below the four holes of the inner tube.
    I'm not sure I am seeing these holes.
    I have the fork I am working on full of oil up to the top of the piston rod and all the air bled out.
    Using a oil measuring tool I have the level 25mm below the top of the outer tube with the piston and outer tube fully down.
    This puts the oil just above the 22mm bolt groove of the piston rod.

    I've essentially done this, but not the final step of setting the oil level as I do not know the number to set to.
    http://www.youtube.com/watch?v=glG3gUjxjEU
    #20