05 950 Adventure fork rebuild

Discussion in 'KTM 950/990' started by zoeper, Sep 29, 2019.

  1. zoeper

    zoeper Adventurer

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    #1
  2. zoeper

    zoeper Adventurer

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    Had to make a tool to get the fork caps off first. IMG-20190928-WA0021.jpg
    #2
    Misery Goat, anydavenow and Helibee like this.
  3. zoeper

    zoeper Adventurer

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    Working end.. IMG-20190929-WA0000.jpg
    #3
    Helibee likes this.
  4. zoeper

    zoeper Adventurer

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    One of the adjuster tubes didn't look good and had some hard residue on it. IMG-20190929-WA0004.jpg
    #4
  5. zoeper

    zoeper Adventurer

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    Forks taken apart. IMG-20190929-WA0006.jpg
    #5
  6. zoeper

    zoeper Adventurer

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    Valves were both stuck. IMG-20190929-WA0012.jpg
    #6
  7. zoeper

    zoeper Adventurer

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    This is the seal kit I got from KTM. IMG_20190929_153600.jpg
    #7
  8. zoeper

    zoeper Adventurer

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    And the stronger springs. These measure 5.5mm vs the 5.2 mm springs that was installed. IMG_20190929_153748.jpg
    #8
    zedtours likes this.
  9. zedtours

    zedtours Been here awhile

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    That is quite a tool, I used large circlip pliers and lever!
    #9
  10. DirtyADV

    DirtyADV Long timer

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    Common that the rebound adjusters are stuck on these forks.

    Good to break them apart all the way.

    Doubt that is ever done by most places if handed in for an oil change unless you specify it and you will probably pay a heafty price for it.

    /Johan
    #10
  11. zoeper

    zoeper Adventurer

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    What else should be checked on these Forks? I plan to give everything a good cleaning and replace all seals and sliding rings. Hope the rebound adjusters clean up well enough to function again. Glad I saw the damage and didn't just do the oil change and left it.
    #11
  12. Stephen

    Stephen Long timer Supporter

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    Yes, good you saw it. When I redid my 04, the dealer pointed me to the "new overhaul kit" which updates the 04 forks to the, uh, much more modern spec. Has all you need and costs less than seals and dust rings. Works great. Yours may already be updated, as the original springs are 4.8 IIRC. The kit is nevertheless the way to go.
    #12
  13. DOREY76

    DOREY76 Been here awhile

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    I'd be checking the compression/rebound assembly whilst you're there. I also noticed some inconsistencies in my valve stacks. IMG_20181129_161338_01.jpg
    #13
  14. anydavenow

    anydavenow Long timer

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    That is a thing of beauty, well done! Although I think you might want to rephrase that as "wanted to make a tool"—I use a $10 one of these!

    :lol3

    c3af8ac3-29d9-4894-a9e4-8e8bdb7b60ec.jpg
    #14
  15. zoeper

    zoeper Adventurer

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    Well Dave you caught me. Had the beer, the tools, the time and the materials. Also used the time to get myself "in the zone" for the job to follow. ...but yes, mostly because I wanted to! :)
    #15
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  16. anydavenow

    anydavenow Long timer

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    Haha. Well, I can only dream of having the skills to procrastinate at that expert level!
    #16
  17. zoeper

    zoeper Adventurer

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    There is a lot of conflicting info out there on fork oil levels. Does anyone know the "proper" height? (Or what can I use as a good starting point?)
    2005 950 Adventure
    #17
  18. gearheadE30

    gearheadE30 @LC8Adventures Supporter

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    Oil height is a tuning tool so can vary, and I usually run 100mm on my 265mm travel suspension. 90mm is the max I ever see people run, and usually the range is 120mm up to 90mm.
    #18
  19. ander2j2

    ander2j2 Adventurer

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    Can you link to the kit?
    #19
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  20. anydavenow

    anydavenow Long timer

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    I also run 100mm on my 210mm forks. I can't remember where I got that from but do remember spending hours trying to find it at the time!
    #20