Need to replace fork caps but not sure what model they're from

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by V4Moto, Feb 12, 2018.

  1. V4Moto

    V4Moto V4Moto

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    I have a set of WP 48mm on a custom build (not a KTM). I have leaking fork cap and want to replace it but it would be easier if I could i/d what year and model range the forks are. Here are a couple of pictures if anyone has an idea from this it would sure help me. It has the black rebound adjuster on the top

    Attached Files:

    #1
  2. DirtyADV

    DirtyADV Long timer

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    Seems to be from an Adventure model, has the adjustable preload.

    Why do you need to replace?

    The one in the pictures looks in good condition at least.

    Cap from any 950/990 adventure should work.

    /Johan
    #2
  3. uk_mouse

    uk_mouse Aquatic adventurer

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    Yeah looks very much like the cap from my 2004 950 adventure, but as Johan says, i think all the adv models had the same.

    Although mine don't have numbers stamped on the top face.
    #3
  4. V4Moto

    V4Moto V4Moto

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    I took that one off the left fork which I had a shop put a new cap on while they were revalving the forks as it was leaking and a change of o rings did not cure it but it seemed expensive, over $300 Cdn for the one cap, now the right side is leaking so I want to replace that side myself but need to buy the correct cap first time if possible.

    Thanks for confirming the 950 caps will work Johan and uk mouse

    Attached Files:

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  5. DirtyADV

    DirtyADV Long timer

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    If its leaking out of the rebound adjuster. The seal on rebound needle has likely failed.

    /Johan
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  6. DirtyADV

    DirtyADV Long timer

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  7. DistortedAxis

    DistortedAxis GO

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  8. godwinmt

    godwinmt They call me Crash

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    Those are caps from the WP 4860 MXMA PA forks which are any of the late model WP 48mm open forks found on katos. You're not just limited to adventure/super enduro models, but any of the 08-14 XC-W, XCF-W, or EXC models will work. Stay away from SX, SX-F, XC, or XC-F models, or any of the 4cs forks.

    As others have said though, they are pretty bulletproof and can be rebuilt easy. Odds are there was either an o-ring left out, or an o-ring was pinched or rolled during install. Where exactly are they leaking from?
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  9. Retired and lovin it

    Retired and lovin it Been here awhile

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    Yes I have these forks on my 200 KTM XC they are the 4860 inverted non cartridge fork.
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  10. MCCOYBOY

    MCCOYBOY Been here awhile

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    Either the rebound needle o-ring has failed (common) or the rebound adjuster o-ring needs replaced. Either way a competent shop should be able to resolve the problem without the purchase of an expensive cap assembly.

    If you decide to go with a new cap I have a few I'd sell.

    Attached Files:

    #10
  11. tomdubz

    tomdubz getting there

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    Was the fork itself overfilled?
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  12. Johnf3

    Johnf3 Long timer

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    You are going on an expensive wild goose chase. If there is oil inside of the rebound cartridge (it is supposed to be dry), then the cap will leak no matter if it is a brand new cap, had brand new parts, or whatever. It WILL leak. The fact that you had a shop working on these already and they began leaking right after that is a tell tale sign.

    Again, the cap WILL NOT seal if there is any oil inside the cartridge. I always cover the hole with my thumb as I pour oil in to fill the tubes. There are many "professional" shops that have no idea that oil does not belong inside the rebound tube.
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  13. V4Moto

    V4Moto V4Moto

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    Think there may be something in that, they never leaked at all before i brought them in to be revalved but started leaking on the way back from the suspension specialist, left side leaked on the floor mat as they were laying down so I took that one back and was told the o rings had all been replaced so it must be a faulty cap so $300+ later the left side no longer leaks (yet) but the right side does. I will try to wipe off the spill and keep an eye on it to see how much it looks like I'm losing for now. If I do decide to go the cap route I'll contact McCoyboy. The leak appears to be from the black plastic rebound adjuster. I kept the original left side one that got replaced so I will see if I can get it apart, there looks like a picture of the parts broken down in the link from DistortedAxis.

    Appreciate the replies - now I know they are WP 4860 MXMA that will help
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  14. DirtyADV

    DirtyADV Long timer

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    Sadly shops these days are not repairing but rather replacing (many times unnecessary but hey they make money tricking unknowing customers to buy parts they dont really need).

    And good luck getting a shop to admit they are at fault.

    The more I have to be in contact with shops and other forms of hired help the more I want to move to some remote cabin and live off the land.

    /Johan
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  15. V4Moto

    V4Moto V4Moto

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    Ironically I live quite a way from any town or city and wouldn't change that but sometimes it can be frustrating, couriers won't deliver out here so you have to drive in to a town to pick up your stuff, I need to buy a 4 pin wrench to remove the top cap and that will take 10 days to get here, then if I get this apart I'll order the o rings (thanks for the parts finder) but will need to drive into the city 100 km to pick those up. You learn patience.

    I removed the retaining wire ring at the bottom and the black rebound adjuster at the top but cannot move the rebound 24mm hex at all. I tried the ones on the bike the newer one that was replaced moves fine but the remaining original one on the right side is really stuck just like this spare one I'm trying to dismantle. Maybe they are not meant to move?
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  16. Johnf3

    Johnf3 Long timer

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    You have oil in the rebound part of the cartridge. 99% positive. I have seen this many many times on these forks. The oil leaking out will not hurt anything but they may leak for a while depending how much oil was spilled in there. They have to be disassembled to get the oil out but it is not hard to do. Save your money there is nothing wrong with you caps.
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  17. V4Moto

    V4Moto V4Moto

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    Thanks John f3 that’s good advice and enough reassurance I will just keep a close eye on the leak but leave it be unless it changes. I learned a lot from this post so thanks to all who responded



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