WP48 - Changing Fork Seals

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

  1. James Siddall

    James Siddall suspension guy

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    100mm from the top with the outer tube pulled down is the common choice. Be sure you pull it all the way up and recheck after the filling as oil is commonly trapped between inner and outer legs giving a false reading, and an overfull leg.
    #21
  2. McVick

    McVick Been here awhile

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    I also found it difficult to tighten the cartridge back into the bottom of the fork leg.
    It threaded into the piston rod just fine but getting it as tight as necessary is a bit of a trick.

    The WP manual says to bend the piston rod a bit by pushing it to the side and holding it while you tighten the cartridge but even doing that I am concerned it is not as tight as it should be. Spec is 25nm but I do not have my torque wrench with me.

    Brian
    #22
  3. McVick

    McVick Been here awhile

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    Thanks James!
    I just tried calling your office to ask you guys.
    You put the Super Plush suspension on this bike originally!

    Brian
    #23
  4. BoulderGuy

    BoulderGuy out ridin'....

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    A cheopo 7/8" wrench ground down works great. And +1 for 100mm air gap measured with springs out, fork slid all the way down on the inner tubes....Make sure to purge the air out by pumping the rod up and down a bunch. I believe Jeff Slavens has a good video of how to purge the air..

    http://www.youtube.com/watch?v=glG3gUjxjEU
    #24
  5. McVick

    McVick Been here awhile

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    One, One fork leg done!
    #25
  6. Johnf3

    Johnf3 Long timer

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    Yes. R14020 I think is the right part number. It comes complete with SKF seals and the updated low friction KTM bushings as well as some smaller seals that are specific to the closed chamber forks that you will not use on the open chamber forks the Adventure has. For around 100 bucks, it is the best value I have found.
    #26
  7. Konflict Motorsports

    Konflict Motorsports KM TUNER

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    Using a small impact (Makita, Dewalt) with the proper setting helps alot too. Pull the cartridge rod to the side, as well as using the impact will get it tight.
    #27
  8. UngaWunga

    UngaWunga Mosquito bait

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    Bam! thanks

    http://www.ktm-parts.com/R14020.html

    Hmm... while those are listed as a kit for SXS WP 48mm, all the rebuild kits listed for 950/990 advs have different (lower) numbers. Is that number correct? Just want to double check. I have to tear down my forks this winter because one of the adjusters is stuck, might as well replace seals while I'm in there. Thanks.
    #28
  9. McVick

    McVick Been here awhile

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    Wow,
    that's a good deal for just about a complete service kit.
    #29
  10. Johnf3

    Johnf3 Long timer

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    The bushings and the seals are identical between the closed chamber and open chamber WP forks. So, yes the kit I referenced will work. Like I said, the kit is designed for WP CC forks, so it has a few extra small seals meant to rebuild the cartridge seal that the open chamber forks on the Adventure do not have. There may be a SKF kit that KTM sells for open chamber, but I do not know the part number if there is one.
    #30
  11. Konflict Motorsports

    Konflict Motorsports KM TUNER

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    You will have 2 extra seals left over (the small damping rod purple seals) otherwise its the same. Its a great price for what you get! There was a major B/O on these a while back, some dealers are still having issue's getting them.
    #31
  12. Johnf3

    Johnf3 Long timer

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    An easy trick is to slide the fork spring in and then invert the fork so the compression valve is facing up at you. Put your 19mm socket on the compression valve and press down as you tighten the valve body. The spring pressure from the fork spring will keep enough force on everything so it tightens right up. Don't overtighten your compression valve!
    #32
  13. Peanuts

    Peanuts Long timer

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    No need to touch the seals to sort out an adjuster. In fact no need to remove the cartridge. Base valve unscrews out the bottom. Cap unscrews off the top, then hold the cartridge with a 8mm or slimmer wrench, then undo the cap off the cartridge by undoing via the preload hex.

    Make sure the ally tube in the centre of the cartridge is almost flush as its a common mistake to assemble the cap onto the cartridge when the ally tube is not correctly seated. Also make sure the black plastic needle in the cap fits into the ally tube as your place the cap onto the cartridge.
    #33
  14. UngaWunga

    UngaWunga Mosquito bait

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    Thanks for the tips.
    #34
  15. KTMSER

    KTMSER Big bike friendly

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    #35
  16. SikDMAX

    SikDMAX Been here awhile

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    Bumping this up.... having a bitch of a time getting the last bushing to seat putting the inner tube back on the outer - even tried heating as the recommend for removal. Any ideas?
    #36
  17. Johnf3

    Johnf3 Long timer

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    I always use my seal driver to tap the bushing into place before I tap the fork seal into place. It just takes a few light taps, very light taps. If yours is not going together easily something else is wrong. You sure your bushing is the correct one?
    #37
  18. keener

    keener Speed changes you.

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    Old thread but very related to what I am dealing with now.

    I got the KTM service kit for my 04 950 ADV. It has SKF seals.

    It came with only one set of bushings. I contacted the dealer and they say it supposed to have two sets. One goes at the bottom and the other clips on at the top.

    However, my forks had THREE sets. The dealer says the middle bushings are not needed !:huh Is that right?
    #38
  19. StevenD

    StevenD Hmmmm, dirt!

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    They cause extra friction and are left out on a lot of rebuilds. They will delay ware a little bit when in, so your choice..

    Verstuurd vanaf mijn LG-D802 met Tapatalk
    #39
  20. uk_mouse

    uk_mouse Aquatic adventurer

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    I found that without the 3rd bushing, my forks had what I consider to be unacceptable play.

    I was trying to reduce stiction, but in my case, putting the SKF seals in was sufficient. They are as good as people say.
    #40