Ktm Fork Seal Replacement

[Paul FaheyMember]

Hi All

The fact that I am asking this question may be the answer to my question… anyway here we go!

I have a 2006 KTM 450EXC. I have had her since new and yesterday I noticed a pool of oil under the fork leg, again. I had tried to clean under the fork seal with a feeler guage but I dont think the problem is going to go away so simply.

So my questions are:

1 What type of fork do I have, ie dual cartridge, dual chamber etc etc

2 Based on the fork that is in the bike, is changing the seals and fork oil something that I should try at home?

I was watching youtube and found some good RockyMountainATV video’s on doing the seals and suggestions on the tools required. Some forks seemed easier to do that others. Just not sure if I have the easier or harder fork type.

Excuse my ignorance but new to this and normally just get the mechanic to do it. Just thought that it would be good to give it a go – maybe learn something!

Thanks
Unit

[ChrisMember]

Don’t know much about it myself but my thoughts are try it yourself then if you stuff it up take it to your mechanic, otherwise I’d never learn anything new, there’s gotta be some vids on you tube somewhere for your bike.

Chris.

[alanMember]

have a crack at it your forks are not duel chamber same as the ones in the video

[Craig HattonMember]

Hi Unit
Will be doing mine, today or tomorrow afternoon, so will let you know how hard it is

Hatto

[murph the surfMember]

Hey Dudes
If you PM me an email address I will send you the manual for the 04 model Kato
I have the 07 model and have done the seals a number of times on my kids 03 200 KTM and my 525. Pretty easy job.
Cheers
Murph

[Mick DMember]

chris72a wrote:

Don’t know much about it myself but my thoughts are try it yourself then if you stuff it up take it to your mechanic, otherwise I’d never learn anything new, there’s gotta be some vids on you tube somewhere for your bike.

Chris.

Mechanics rates

$85 per hour
$95 per hour if you hang around and watch
$200 per hour if you’ve already had a go yourself and stuffed it up.

[ChrisMember]

micknmeld wrote:

chris72a wrote:

Don’t know much about it myself but my thoughts are try it yourself then if you stuff it up take it to your mechanic, otherwise I’d never learn anything new, there’s gotta be some vids on you tube somewhere for your bike.

Chris.

Mechanics rates

$85 per hour
$95 per hour if you hang around and watch
$200 per hour if you’ve already had a go yourself and stuffed it up.

Just put em back together and pretend you never touched em 😆

[murph the surfMember]

Just sent Hatto the fork seal manual
I may have my sons pics and description of just seal replacement in case you tend to get bogged down with all the other shit you don’t have to touch eg valving and stuff. Will have a look for it this arvo
Did you receive the manual Hatto?
Cheers
Murph

[Craig HattonMember]

Murph the surf wrote:

Just sent Hatto the fork seal manual
I may have my sons pics and description of just seal replacement in case you tend to get bogged down with all the other shit you don’t have to touch eg valving and stuff. Will have a look for it this arvo
Did you receive the manual Hatto?
Cheers
Murph

Cheers Murf, looks great. will be doing this arvo, am going to try and do a how to for the thread

cheers Hatto

[mikeMember]

I’ve had a go at doin seals before and was never happy or real confident. These days I get the guy at East Maitland to do it. He charged me $70 to do one side as it was the only one blown. That included oil. I just took the fork leg in and he sorted it out. He seemed to do a good job and I was happy with the price.

[Craig HattonMember]

Dusty wrote:

I’ve had a go at doin seals before and was never happy or real confident. These days I get the guy at East Maitland to do it. He charged me $70 to do one side as it was the only one blown. That included oil. I just took the fork leg in and he sorted it out. He seemed to do a good job and I was happy with the price.

Dont let him out of your site dusty, local bloke hear is $190 for 2, with forks out of bike

cheers Hatto

[mikeMember]

Dont let him out of your site dusty, local bloke hear is $190 for 2, with forks out of bike

cheers Hatto[/quote]

no worries mate…will do. Hope ya get it sorted either way.

[Paul FaheyMember]

Hi All

Thanks for your responses and sorry about my delayed response.

I considered Mick’s response and thought hmmm, have to take another bike to the mechanic anyway, haven’t really got the time to do them, what the hell, take both bikes and get the KTM’s value clearances checked etc.

I will try my hand at something easier.

Thanks again.
Unit

[Craig HattonMember]

Hi Unit
Sorry for the delay, but to change mine over was very simple 1 hr max, it really is simple-just need to be clean.

Tools we used.
Rattle gun, 19mm, 17mm, special fork seal tool-but easily make your own, rags, oil, seals, something to remove spring clip inside tube.
I had a mate show me how but this link is exactly how we did it.

http://www.dirtbikeworld.net/forum/showthread.php?t=16751

regards hatto

[Neil GordonMember]

bit late i know but as hatto said, pretty easy and if you have a rattle gun you can completly dissassemble and do the job PROPERLY. it is not such a hard task as some make it out to be although there are a few crucial steps that must be taken when doing the job so as not to stuff it up. if you follow these it is pretty simple, once you do it a few times you will wonder why you ever paid someone to do it.
for anyone in sydney that wants to give it a shot but isnt quiet confident in doing it. i am more than happy to help out

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