KTM WP Semi-Active Fork Rebuild | KTM 1190 1290 | Back in the Garage

In this episode of Back in the Garage, I rebuild the WP Semi-Active front forks on my 2016 KTM 1290 Super Adventure. I replace the seals, bushings and oil to freshen up the front end since the bike now has over 51,000 miles. on it. While it requires a couple of speciality tools, they are inexpensive, and the job is pretty easy. I've listed all the necessary parts and tools below.
Seal Kit: KTM RP10012T (available from RockyMountain ATV/MC under OEM KTM)
Bushing Kit: KTM R14047T (available from RockyMountain ATV/MC under OEM KTM)
4WT Oil (available from RockyMountain ATV/MC under OEM KTM)
Dielectric Grease: amzn.to/37bpbMa
KTM Special Socket T14071
Spanner Wrench: amzn.to/3K9HWP0
Measuring Cup: www.rockymount...
Motion Pro Fork Seal Tool (48mm): www.rockymount...
Tusk Fork Seal Driver (48mm): www.rockymount...
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Mario Orsini
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Bunker Hill, WV 25413
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[@smoke05s]

One tip to save money on special tools. I learned this from rebuilding my CR250 forks (from a KZbin video). To drive the seal and bushings in you don't really need the 50.00 seal driver. All you need is electrical tape. layer it up so it is at least half the thickness of the seal. Be careful to keep it lined up to keep the line sharp. it will be straight enough even if you are a little sloppy and will drive the seal in just as good as the special tool. Just clip in the retainer clip (so it snaps in place), then unwrap the tape in that order in case you need to go in a little deeper. Then push the dust seal in by hand

[@greedyg76]

Dude, another perfectly timed video again! The time you've taken over the years to document everything on this bike, is greatly appreciated by the SAT crowd, keep 'em coming...

[@dimosk7389]

great video once again... this playlist is slowly turning into a "motion picture workshop manual" for the 1290 lol amazing stuff

[@2WR]

Yea, quite the catalog has been built so far.

[@adventureswithvs6461]

Thank you for this video. I’m not the least mechanical guy in the world, but having this to rely on was a huge help, especially as someone who has never rebuilt a set of forks.

[@2WR]

No prob. They aren't much different to service than standard forks.

[@carlosfigueiredo415]

Thank God, my brother is a suspension technician and he completely re-valved my extension leg with a Kayaba valve and for me it was a master improvement.

[@superdave8752]

Woooweee!!! Mario, I can't thank you enough brother, just popped the Front Wheel back on and bout to go for a test rip! Thanks a bunch dude🤟😎🤟

[@Hoshi_Toranaga]

I love your videos. You actually make it so simple for us that it takes away all the fear I had working on my bikes. Funny enough I am from Austria, next time I drive by KTM in Mattinghofen I will tell them to make a thank you shrine for you hehe

[@2WR]

Haha! I was over at the KTM Motohall in Mattinghofen back in 2019…they did NOT have me on the hall of champions 😂

[@MitchellsMike]

Super explained and extremely helpful if you want to take care of a maintenance of the damper system on your motorcycle for the first time 👍🏻 Likewise, it is always nice to see my own motorcycle in a good video 😉 Keep it up 👍🏻

[@carlossheppard1745]

I have the exact same and make 1290 and my right fork seal just went last week with 62,000km on it. Took it to the KTM shop to have them replaced but will do it next time myself, thanks for showing the process.

[@danhill7525]

Managed to blow mine out riding hard off road again, so I think its time I learnt how to do this, and as always its the perfect video.

[@ThePastalavista]

Thank you! My seals just blew the other day on my 1290 this video helps alot! Keep up the good work!

[@2WR]

Glad it helped!

[@ogyedanjuma7413]

I’ve waited for this video for years! Thank you Mario 🙏🏽

[@buaan]

I did a similar job on my 990A (non-active type WP), the Motion Pro Seal Bullet was a must have, I tried with other methods (cling film etc) and the seal must have torn as it leaked and I had to go at it again - with the bullet the seal slid straight on no problems. Great tutorial.

[@Millektm]

Great video, thanks Mario,will come in handy when I get around to doing mine.

[@MagnumMuscle1000]

Another great video from Mario. Thanks!

[@2WR]

You're welcome!

[@richard530d]

Thanks! there will be something to do this week ... 😉

[@ianferrier235]

Good job Mario 👍🏻👍🏻

[@radovanweber3329]

super video, thanks, my ktm 1290 SAT 2015 is 120 000km :-)

[@seazv]

Dude thanks to share, this channel is amazing. Questions How is the feel with the forks in the top ring position for offroad and low speed in trafic do you get it more estable? to just change the oil without seals change i still need to loosen the bottom screw of legs the one close to the axel. Thanks dude.

[@xltman8]

Wow!! I totally appreciate the information given here. I however have a 2016 1190S with active suspension but my forks have 2 springs, one in each fork. Anyplace to find out what amount of oil goes in those types as the 1290 forks even have different elec caps.... a spanner pin type wrench cannot be used.🤷‍♂️

[@2WR]

Best I can say is download the service manual. print.ktm.com/

[@stevepickford3894]

Great video, thanks. 👍 I have a 2017 1290 Super Adventure S & find the forks too stiff even on the comfort setting. I've looked for softer fork springs, not found any yet. My concern is that fitting softer fork springs will confuse the electronic suspension, leading to error codes on the dash - any thoughts on this? Thanks in advance 👍

[@RetirementVille]

Fantastic tutorial. Thank you.

[@2WR]

You're very welcome!

[@asiantechhk]

A M A Z I N G ! ! !

[@robbiemcgrath3792]

Great video

[@DDCgarage]

Not even 10 thousand miles mine are leaking. 2019 super adventure s. Hope it’s the same forks and style as I ordered the kit already. 😆

[@Fonzer007]

Great video! Like your channel! Beste bike ever 😉

[@2WR]

Thx!

[@christophermcreynolds6001]

Great job thanks for it.

[@rubensilva78]

When you top the oil , isn't it supposed to pump the fork to push air out? Btw great channel keep up the good work😊

[@2323kjm]

Great video!!! Have you did a video on rebuilding the rear shock? I'm guessing not cause I couldn't find one in your videos but there are a lot lol

[@2WR]

No. The rear shock isn't technically rebuildable but I'm working with my suspension guy on it sometime later this year. Unless you have the proper tools (plus nitrogen and a vacuum/bleeder pump) the rear shock will not be DIY for most.

[@robclayburn356]

I really appreciate your back in th garage video's. Even though this one was a little late for me. 😀 I bought my 2020 SAS and about 1000 miles in, the right fork started leaking but of course the dealer and ktm told me that it was a wearable item so I was responsible for replacement. Replaced both of the seals with KTM seals and the right fork still leaked after another 500 or so miles. Took only the right fork apart and couldn't see any burrs but ran some 5000 grit and polished it and used a new Pivot works seal and haven't had any problems since. Around 8000 miles since the last seal change. One question though, the service manual calls for heating up the outer leg before pulling it apart and setting the seals on assembly, do you think that is a waste of time? Thanks for all of you efforts!!

[@2WR]

All depends. U can heat them up if you need to but I’ve not had to do it on any set of forks yet.

[@robclayburn356]

@@2WR Nice. It was a pain in the ass heating them up. I'll skip in next time. Thanks again.

[@worldofeden9743]

I have a 2016 KTM 1190 R can’t seem to figure out if the same parts and process apply as I have been unable to confirm if the OEM forks are semi-active or not. Has anyone confirmed this?

[@daved4094]

Great video. I was apprehensive about doing the seals when the need arises but your video makes it look do-able. Do you know if it would be the same WP forks used on the Triumph Tiger 1200 semi active system. Many thanks for the comprehensive instructions.

[@2WR]

They aren’t exactly the same but should be similar enough.

[@daved4094]

@@2WR OK thanks a lot.

[@woweeoi11]

Had mine done at about 35k but will reference this the next time they start leaking! Thanks for the videos as always, how's your 350 been?

[@2WR]

The 350 has been neglected lately. Hoping. tohave it back out in a few weeks.

[@Near2Future]

I've got a 2019 superduker is everything the same apart from the semi active caps? I've got 18k miles & it's started to leak.

[@paulbourgoin2436]

Mario, awesome video as always!!! As we had previously talked about, my right seal was leaking a bit at the end of the 2021 season. So over the holidays, I did the seal mate thing and looks like it did the job. Oil leak seems to have stoped. But I have not gotten the bike out yet as our winter here in Canada is still going on. But I should get the bike out at the end of April to see if the seal mate worked. My SAT only has 16 000km on it so I hope I don't have to pull everything apart. Some do a heavier oil when they do the forks, any thoughts on that? Benefits ? Mario, you are a legend!!! Love your vids... 😀

[@paulbourgoin2436]

well, I went for a ride today and I guess the seal mate did the job... fork was dry as a bone... Lets hope it holds..

[@2WR]

Glad all is well!

[@manuelgonzalez-lr2pv]

hello 2 Wheeled Rider, nice video by the way! just a question. I have the same bike and I want to know if it is possible to add a manual preloaded monoshok like the R version mono and it still works with the semi active suspension in the front without this "SUSPENSION" message on the panel because if you got this alert it will automatically lock the semi-active and suspension modes only in mode 1 and almost for me in hard sport mode. I want to say that the optimal situation will be to keep the modes semi-active and only on the front suspension. Can we have this setup?

[@gregorybergandy7737]

Salut, dis-moi le boulot hexagonal pour visser le ressort je n’arrive pas à doter il tourne sur lui-même mais ça ne fuit pas. Qu’est-ce que ça fait la même chose pour toi ?

[@jaronard1]

What age and miles was your bike at when you had to do this service? I have a 2019 SAS, about 30 months in service with just over 30K miles, but haven’t seen a need to do any suspension work yet. It appears you needed to service the forks because a fork seal wore out? Fantastic video with great detailed explanations. Thanks for sharing.

[@2WR]

Realize folks don’t watch every video but bike has over 50k miles on it. Oil/Seals/Bushings we’re getting replaced regardless of the one seal leaking as they were way over due. Fork oil, just like any other oil/fluid breaks down over time. And thx!

[@jaronard1]

@@2WR it’s a little surprising there’s generally no way to change the oil without repairing the entire assembly, knowing that suspension oil does breakdown over time, like all oil. I’m guessing fork seals usually breakdown by the time the oil does. But congrats on 50K, hopefully many more to follow!

[@hottfats]

Another great video mate. Thanks. Just to clarify if you say right and left fork does it mean when you are sitting on the bike? Cheers

[@2WR]

Yes

[@hottfats]

@@2WR cheers mate. Ride safe

[@RaYama]

Hi, great video. Did you also service the rear shock absorber?

[@2WR]

No. While technically it’s non-serviceable, a few have been successful. However, most haven’t.

[@rickylee1628]

Another awesome video. Question: I have the 2015 Super Adventure. Is it the same seal kit? Web sites only list the 2016... Thanks!

[@2WR]

Same one.

[@nicholas2932]

is it possible to leave the fork in the bike, take the top cap off and the bottom bolt out to drain the oil? or would it just never drain all the way...

[@2WR]

No

[@MarkPrendergast]

My right is laeking. Dumb question? When you reassemble, is there any realignment necessary or does it all line up back in the original position (no twisting)? Great video

[@2WR]

So long as you get both forks at the same height in the triple clamp the rest takes care of itself.

[@cmlago]

Una consulta: los dos aros plásticos rojos que vienen con los retenes, para que son? Pedí los mismos repuestos y tengo la misma moto. Muchas gracias y saludos desde Argentina !!!

[@2WR]

The silicone rings? They just for helping set sag.

[@motologylmm2522]

Thank you for the video, one question. Did you disconnect the battery before the job?

[@2WR]

No

[@Bialy092]

Hi, I have a question have you ever encountered the problem of rattling suspension ? I have a problem that when I bounce the fork it feels a knock on the handlebars, supposedly a known problem and even in new motorcycles it hits .

[@2WR]

No, I haven’t. Check the recall/tech bulletins. There were some models that had a recall for suspension issues. I don’t remember the specifics.

[@Bialy092]

@@2WR Unfortunately, there was already a software update. the strangest thing is that some pieces have it and others don't...

[@matticable4616]

Great video, watched it many times.... I was able to Change my fork seals. I do have questions!! When riding up a curb at slow speed feels like something is loose. I am thinking Head bearing might be wearing out or might it be something else. Not the forks or tire... Any thoughts

[@matticable4616]

is it a "Suspension Cluck" that 1290's seem to have??? If you know of a fix, please let me know.

[@2WR]

never had any "suspension clunk" on my bike. I'd start by checking your head bearings

[@BALKAN-pv6mh]

Merhaba İstanbul dan yazıyorum 1190 almak istiyorum daha önce ktm hiç kullanmadım 20 bin km de tavsiyene ihtiyacım var alayım mı?

[@bikerboi1983]

No need to bleed the fork at all before fitting top cap?

[@crja2728]

Hello, these semi active wp suspensions are the same ones used by the tiger 1200 xrx 2019?? Saludos

[@2WR]

No

[@RayTeerlink]

Since you have the semi active suspension that means it's not an r model is that right? I was leaning away from the r model because I hope to do longer pavement rides like you do, with only occasional dirt roads

[@2WR]

2016 KTM 1290 Super Adventure.

[@ehiggins7476]

Going to do oil and seals on my Husqvarna Svartpilen 701forks, the procedure is probably very similar as far as the parts and sequence. Is there a particular way to align the fork legs once you put them back on the triple clamp to ensure the front end is straight? I was just gonna make a reference mark with a paint sharpie on the triple clamp. Any other suggestions? Thanks

[@2WR]

So…u obviously want to ensure u have them on the same line or whatever mark u want to use to get them equal in the top of the triple clamp. That’s it’s. Ensure u properly tighten/torque the axle. (Inner tubes spin in the outer tubes)

[@McDee_Rick]

Hi, Already did a rearshock rebuild on yr 1290?

[@DungNguyen-fj2wp]

I’m getting my done soon and wondering how to make sure both forks square up for the wheels?

[@2WR]

Get them lined up in the triple clamp and properly torque the pinch bolts and axle nut.

[@modestoocasio8875]

I believe my 22 1290 Super Duke R Evo has similar forks. Is it possible to make the forks shorter to lower the front end of the bike by 2-3 inches? Maybe different springs or trimming the springs? Any information would be very helpful thanks!

[@2WR]

I don’t see how that would be possible considering you only have 4.9” of travel to begin with.

[@davebarlow4337]

Hello there mate, had my forks done at KTM dealership, however it seems to be really unstable over bumps and small which is lost me any ideas what's wrong with them

[@2WR]

Start by checking the reinstalled them properly (axle aligned, forks aligned, etc). If that checks out then you know your answer, they messed something up when they serviced them.

[@AntaresSQ01]

Am I tripping?? No spring in the right fork leg?

[@2WR]

Nope

[@jeongkipark3415]

How much oil should I put in when I do 1090R Front Suspension Overhaul in 2018?

[@2WR]

Check your service manual. I don't have a manual on hand for every bike

[@vood00samurai]

You going to attempt the rear shock?

[@2WR]

I’m not. I have my suspension guy in contact with WP. Long story, short…ain’t easy.

[@vood00samurai]

@@2WR I think I read somewhere you needed special equipment to do it

[@hottfats]

@@2WR what are you changing in the rear shock mate?