Hey Rocket this is from TT KTM thread, I got it for a mate who had probs with his seal on ktm 450. Dont know if it will help?
Fork seals leak: To fix this get aftermarket seals, I use Synergy brand if I have to change a set. The other thing many guys swear by is cleaning them with the film method. I have done this on my bike, which has stock seals, and it has always stopped the occaisional leak. Have not had to replace these since I got the bike alomost 2yrs ago.
Counter shaft seals leak: Again some guys never have a problem and others cant get it to quit. This system is as follows,from the inside out, a thrust washer,an 0-ring,a sleeve,the outer seal,the sprocket and the clip that holds the sprocket on the shaft. This system relies on pressure from all the parts pushing together to seal the system. Some guys have trouble if they use an aftermarket front sprocket as some are too thin. Most of the time the leak can be fixed by removing the sprocket and sleeve and cleaning the outer seal with a q-tip and the other parts by removing and wiping off. There are new part numbers with thicker o-ring and outer seal starting in 05 that will fit the older bikes as well and fixes most chronic leakers. Often the leak will start after a mud ride or when the bike is left on the side stand for an extended time. Some dont worry about it and call it an auto chain oiler. I have fixed two of the three 200’s I have owned and never had to replace the parts again, but have had to clean one, one time. The other cause, and a thing that can break the case, is adjusting the chain too tight
