KTM leaky fork seal replacement

[@GreaseAndGravel]

This is the best video on fork seal replacement I've seen, thanks man! I am doing mine at the weekend. Exact same forks but on a 1996 KTM 250 EXC. Cheers

[@TomsTinkeringandAdventures]

Thanks, hope your forks go together easily.

[@GreaseAndGravel]

@@TomsTinkeringandAdventures Thanks!

[@albertdalrymple8132]

Hi Tom, Terrific & best video on fork seal replacement! I'm going to do the same on my 2005 KTM 525 EXC - Thanks again Tom!

[@TomsTinkeringandAdventures]

@@albertdalrymple8132 thank you. 525 should be pretty similar, good luck!

[@surrontvkobuild]

Great video u don't need cartridge holder I see u don't loosen bottom this awsome I though u need u remove button cartridge valve system

[@TomsTinkeringandAdventures]

@@surrontvkobuild there are ways to get by without taking it all apart or using special tools but it’s a bit more difficult. If you’re only doing it rarely, no problem but if you do the job more often it makes sense to buy the tools.

[@surrontvkobuild]

@@TomsTinkeringandAdventures thank you very much

[@soggysaggz1628]

i need to redo my 04 125sx forks and this was very helpful to watch, thank you!

[@TomsTinkeringandAdventures]

Hope it turns out great.

[@Xrplaws]

Your detail is out of this world, thank you for the informational video!

[@TomsTinkeringandAdventures]

Hopefully it provided some help for you. Thanks for watching

[@jimgriggs2184]

Ahh KGB. I miss KGB. Anywho, very good video, after paying a shop way, way, WAY too much money, the seal is leaking again. Like immediately. So I guess I can give it back and wait a couple weeks, or I can do the job and ride this weekend. Guess I'll ride this weekend.

[@TomsTinkeringandAdventures]

@@jimgriggs2184 they are still playing Stairway To Heaven. 😂 Best of luck with the fork seals. Can’t make it worse!

[@nwhuckin7761]

great and thorough. thanks for the tips, I'll be replacing seals in my 2002 exc 300 tomorrow. this really helps

[@TomsTinkeringandAdventures]

NW Huckin just take your time and you will be fine. Good luck, let me know how it goes.

[@Horners_chopshop]

Hey man, how did you go? I have to do the same for my 2004 exc 300, was it pretty similar?

[@BillWrites-t2e]

Thank you, the video was golden...

[@TomsTinkeringandAdventures]

Thanks for watching

[@daddydutchbbq]

Great how to tutorial ! You’re a pretty handy guy to have around! Great job Tom !

[@TomsTinkeringandAdventures]

Daddy Dutch BBQ And Cooking thanks!

[@mcjustlikenew]

Thank you for the advice and also thank you for not using your platform to just talk used enough information to make it not confusing some people like to talk to you much and it just makes it too much information kind a like this message

[@TomsTinkeringandAdventures]

Kind of funny, some people say I talk too much and others want more.....well you can't make everyone happy but I'm happy if I have helped people out. Have a great day!

[@Dannydanny991]

Great video I'm going back to mine tommorow as off work I'm thinking cut my old fork seal first then pop it back on to shove new one down hopefully it works

[@TomsTinkeringandAdventures]

I used to do that, I just pushed the old seal on above the new one. Use it to set the new seal, then cut it off.

[@Dannydanny991]

Thanks again for video new follower here

[@TomsTinkeringandAdventures]

@@Dannydanny991 I’m actually working on forks right now! Always something going on.

[@rogerkk4znuraywwf396]

Great video it helped me do my 2009 ktm 200 xcw thanks

[@TomsTinkeringandAdventures]

Oh, even helpful on the newer models? That’s good to hear, thanks for watching.

[@volkusa5808]

You make it look so easy.. my lower fork seal could not be seated after one hour and many attempts.. off to the dealer..

[@TomsTinkeringandAdventures]

I am by no means an expert. The nice thing about video is that I can edit out my mistakes. You can at least say that you tried, a lot of people are not willing to even do that. Next time, you got it!

[@ronfrieborn2276]

Thank you. I appreciate your video.

[@TomsTinkeringandAdventures]

Thanks for watching.

[@wisecampmotorcycles8258]

Great video Tom, I need to do the seals on my 2000 model 300exc, I'm guessing the procedure is the same. I've done many old regular forks, but never upside down ones. I'm confident now after watching your video. Cheers.

[@TomsTinkeringandAdventures]

wisecampmotorcycles thank you, yes the procedure should be same. Just look up the capacity, it’s different for most bikes. Good luck and thanks for watching.

[@whoflungdung1487]

Helpful vid have to do my seals and just dont want to screw it up and end up having to bring it to somebody to fix it

[@TomsTinkeringandAdventures]

WhoFlungDung 148 as always, read the manual! 😂. I hope you get it done successfully.

[@MrBowser2012]

Great video!

[@TomsTinkeringandAdventures]

Thank you. I’m doing two sets of forks this week, must be that time.

[@tmlandscaping1378]

My fork seal has a bleeder for the air. But the cap is almost the same any idea how to do it then?

[@TomsTinkeringandAdventures]

Most are the same, just make sure you look up the fork oil capacity for your model

[@Leftbanger1976]

No one ever mentions the rubber and the spring at the bottom of the damper..when I pulled my spare forks apart for a practice, that bit fell out with the damper, but no vid I've seen shows that?? Why not??

[@TomsTinkeringandAdventures]

Hmm, I’m not even certain of which parts you’re talking about. Will have to look at the manual. And that’s why having a manual is good, I know that sometimes things get missed on videos or just not covered completely.

[@Leftbanger1976]

Yeah she's in there 🙂 that's what makes the damper spring back and how the tension adjusts. I just pulled my other forks apart but the damper rod didn't come out ,hence the spring, and rubber valve didn't either. I don't have to complete pull them apart to wash and refill do I?? Like I'm not undoing the nut at the bottom of forks and totally disassemble them, don't think it's that nesacary for my needs..

[@TomsTinkeringandAdventures]

@@Leftbanger1976 correct, just to do a fluid change or install seals you don’t need to remove that…which is why it wasn’t covered in my video. Thanks for checking that out and letting me know, I might have to do a complete disassembly video.

[@Leftbanger1976]

Yes just finished my 2005/525 today was a big day doin them Not a complete pull apart either. SO I HAD TROUBLE WITH PULLING OUT THE SEALS FORKS COME APART BUT THE SEALS WERE LEFT. LOOKS LIKE I COULD IF DONE WITH NEW SHIMS BUT NOT THIS TIME.. SO HEAT GUN DIDN'T WORK AND THEY WOULDNT BUDGE... SO HERES THE SOLUTION I COME UP WITH.. I Had TO BOIL THE FORK IN HOT WATER ON THE STOVE FOR ABOUT 2 MINS IN ABOUT AN INCH OF WATER, THEN SLIDE THE OUTER FORK OVER THE END OF A BASEBALL BAT, AND THEN SIT MY BIG BRASS PUNCH AND N THERE THEN BRING THE FORK DOWN AND HOLD TIGHT AGAINST THE PUNCH AND SMASH WITH A RUBBER MALLET A REALL GOOD FEW TIMES ALL THE WAY ROUND, AND THEY POPED OUT FINNALLY.. OTHER SIDE WAS THE SAME, AND THEY WOULD NOT BUDGE WITH THE SAME TECHNIQUE WITH the heat gun. Only with my idea of boiling them on the stove did the even think about budging!!!

[@TomsTinkeringandAdventures]

@@Leftbanger1976 you had a crazy day of working on your forks it sounds like.

[@BrapKY]

Hi, Tom, thanks for sharing! I have 2 questions. That spacer between the seal and first bushing, was it flat or angled? Mine is angled (both forks) but it popped out and I'm unsure of the orientation. Second, is your lower bushing 'free-floating' on that section of shaft? Mine has no slider, and yours is the first vide I've seen that looks about the same (2006 250 xc, supposedly stock fork). Thanks again!

[@TomsTinkeringandAdventures]

It's been a long time since I worked on these forks, I honestly don't recall....I'm sorry!

[@BrapKY]

@@TomsTinkeringandAdventures No worries, thanks again for a great resource!

[@Glennozrx]

Awesome detail thanks

[@TomsTinkeringandAdventures]

Thanks for watching .

[@bve7397]

Hey man I was wondering where you can find what oil to use, and oil level and such? I have a 125 exc 2005 and its not in the manual, any ideas?

[@TomsTinkeringandAdventures]

There are separate suspension manuals for some bikes

[@bve7397]

@@TomsTinkeringandAdventures I can only find the sxs for my model, but found out oil is kinda preference im just not sure about the level

[@TomsTinkeringandAdventures]

@@bve7397 I always suggest joining a brand specific online forum. Wealth of information available in those, someone will have what you need. KTMtalk is a good one.

[@sparklewcs]

Great help. Thanks

[@TomsTinkeringandAdventures]

That’s what I like to hear!

[@randywolfe44]

Thanks for the video. I think I will attempt it. I can have it done for $350. I can save $250 maybe if I do it myself.

[@TomsTinkeringandAdventures]

Yes, you can do it! Hit me back after you get done

[@randywolfe44]

@@TomsTinkeringandAdventures Well we finally got to it today and it went smoothly thanks so much for the video. 👍

[@TomsTinkeringandAdventures]

@@randywolfe44 my kind of reply, glad to hear it. Enjoy the ride!

[@beretioliver5710]

Hi! I have a 2002 exc 200! Same sticker set. Is this a 43 or the 48 wp fork?

[@TomsTinkeringandAdventures]

I don’t remember which one it is, sorry.

[@cydiahelp1]

Nice vid well explained

[@TomsTinkeringandAdventures]

Thank you.

[@federpmatc]

Awesome video! Thanks. Is there any need to back out the adjusters on the top of the forks, before loosening or removing the top caps?

[@TomsTinkeringandAdventures]

Patrick feder it’s always a good idea to do that, yes.

[@marzrider6452]

Sweet video!! Going to be replacing my 04 EXC 200's Seal's in a couple days, this ought do the trick, one question how much Fork oil did you end up using? the Manual doesn't specify just the weight. Seen another video on "air gaping" with WP forks. I just don't want to put to much or too little oil. Thank's for the super helpful video!

[@TomsTinkeringandAdventures]

MarzRider I’d say the majority of forks don’t list a capacity, you have to measure the oil level...likely the air gap you mentioned. Every model is different so I couldn’t say for sure what yours should be set at.

[@michaelhealy81]

Thank you!

[@TomsTinkeringandAdventures]

You’re welcome!

[@jayhenry7710]

How long did those seals last? Never had any luck with aftermarket seals. I always use oem..

[@TomsTinkeringandAdventures]

They are still working, it’s my buddy’s bike. I have had good luck with aftermarket seals myself.

[@mxgryan]

You've used the wrong brands then my friend.

[@Fishingfrancewitholiver]

Nice one

[@TomsTinkeringandAdventures]

Thanks for watching.

[@emikearizona]

What size is your six point socket brother? Great video by the way

[@TomsTinkeringandAdventures]

I don’t remember what size for this bike, I have a KTM 250SX in the garage and it’s a 24mm for the top caps. Thanks for watching.

[@emikearizona]

@@TomsTinkeringandAdventures another video confirms that it is a 24mm, thank you for your response. have a great weekend, I really enjoyed your video and I'm going to subscribe.

[@TomsTinkeringandAdventures]

@@emikearizona glad to help, hopefully you find a few other interesting things on the channel. 😀

[@emikearizona]

@@TomsTinkeringandAdventures I'm going to start going through your videos because you explain every necessary detail. I have a 2000 KTM 200 and appreciate the video. I'm 60 and I've ridden since 1971 and was never really that mechanical so I'll be definitely checking out your videos. 🇺🇸 I'm pretty excited it's my first KTM. All the parts came in but I need new fork seals of course. I'm going to watch the video again and then during the install. I like your trick using the old seal to press the new one in. I know you've got some tricks up your sleeve besides that, the order of things like when you loosing things up or button her up. You make it look easy but I can use it as a step by step video!

[@TomsTinkeringandAdventures]

@@emikearizona fork seals are a job a lot of people are worried about doing, but just take your time and you’ll be fine. The KTM 200 is a good machine.

[@jackbm250r]

When putting the new seal in how do you know how far to push it in?

[@TomsTinkeringandAdventures]

gixxer_jack it will only go in so far, there’s a machined lip in the fork leg. Also has to go in far enough to get the spacer and snap ring in above it.

[@jackbm250r]

Tom's Tinkering and Adventures brilliant, cheers for the reply and the video, it’s really helpful!

[@TomsTinkeringandAdventures]

gixxer_jack glad it helps, hopefully you can get some riding done.

[@Summit_Moto_Utah]

Freaking genius!!!

[@TomsTinkeringandAdventures]

Hopefully the video helped.

[@EDU_16V]

Hi man, nice video, greetings from Spain, Im just gonna ask you about you said we have to fill the fork with 430 - 465 ml right? It's my only doubt just for being sure about the oil level, thanks man

[@TomsTinkeringandAdventures]

If that’s what I said in the video I likely got the information from the manual. The most accurate way is to measure the level from the top of the forks, always read your manual.

[@EDU_16V]

@@TomsTinkeringandAdventures yes, I ask because my English is not perfect haha, I ll try to find the manual but I actually don't have got it

[@TomsTinkeringandAdventures]

@@EDU_16V what year and model is your motorcycle? I will see if I have the information for you.

[@EDU_16V]

@@TomsTinkeringandAdventures thank you man thank you, ktm 250 sx 2006 ❤️❤️❤️

[@TomsTinkeringandAdventures]

@@EDU_16V from my information you should be using 360 ml for the fork if you have completely drained the cartridge.

[@CortezwithaZ]

That flashlight at the 8:48 minute mark is worth $1M 😳

[@TomsTinkeringandAdventures]

Robert Roy I’m willing to sell it for half that!

[@garajulfaragaraj]

Thank you 👍👍👍

[@TomsTinkeringandAdventures]

Garajul fara GARAJ hopefully you got your bike fixed, happy riding.

[@daddydutchbbq]

Hello Tom !

[@TomsTinkeringandAdventures]

Daddy Dutch BBQ And Cooking hello my friend!

[@razman201201]

DO NOT CLAMP YOUR DOWN TUBE IN A VISE LIKE THAT WITHOUT A RAG OR THE VISE BEING OUT OF THE TRAVEL OF THE TUBE

[@TomsTinkeringandAdventures]

I agree with you, but the vise was not really applying any pressure, only just holding the fork upright. Basically as much pressure as holding it with your hands....it also has hard rubber inserts on the vise.

[@TomsTinkeringandAdventures]

I agree with you, but the vise was not really applying any pressure, only just holding the fork upright. Basically as much pressure as holding it with your hands....it also has hard rubber inserts on the vise.