Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > KTM Tech

KTM Tech KTM Tech Forum - For Questions specific and of interest to KTM riders only. Questions comparing which bike is best etc go in the "Which Bike" forum.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

LinkBack Thread Tools Display Modes
Old 1 Apr 2002
Registered Users
New on the HUBB
Join Date: Jan 2002
Location: victoria, Australia
Posts: 11
Front forks oil leak x2 bikes

Strange bike day today - This morning I noticed a very slight leak from the front forks, oil had made the dry mud a little moist around the base of both the forks. Mates bike had no sign of this. We rode 40 miles (on sealed road) to where we filled up and during this time the seals on my bike gave out and I had oil all over my riding boots from the leak, mates bike developed the same thing but only on the left fork, but 2 hours later his right one let go as well. So summary, after 20K through mexico, central and south america (currently ecuador), riding on rough stuff but not for the last last 400 miles (mainly tar recently), and on one day 4 fork seals go within 2 hours of each other. Any experiance from anyone, any service advice - I've never seen this happen before and dont know realy what to do?
Reply With Quote
Old 1 Apr 2002
Registered Users
HUBB regular
Join Date: Apr 2001
Posts: 99
A quick bodge for the fork seals which may last days or months;
Remove the seals carefully so as not to damage them. Behind the seal is a small diameter spring running around the circumferance. Remove this without stretching or damaging. Cut or find the join and undo. Cut about 5 to 10mm from the spring and then intertwine the spring on itself again so as to form a circle again and refit the whole lot again. This wont help at all if the forks are damaged and causing the leak but if the seals are worn/ tyred it should solve the problem untill you can get new ones.
At least this works on 99% of bikes but I have never done a fork repair on a KTM so its a bit of guess work for me.
The bodger Andy
Hope it works
ps There is a good chance of damaging the seals on removal and fitting so perhaps its better to try this quick fix only if its an urgent repair needed or you could end up with a worse situation.

[This message has been edited by andygray (edited 01 April 2002).]
Reply With Quote
Old 24 Sep 2002
Ian Ian is offline
Contributing Member
Veteran HUBBer
Join Date: Aug 2000
Location: UK
Posts: 427
It's important to remember to bleed the WP forks regularly, especially if you've been riding on a rough surface. I had a leak from one fork on my Adventure but after bleeding them it stopped. It tells you how to do it in the service manual, a two minute job. Remember if ever you have the forks off, you should replace them such that the bleed screws are accessible with a screwdriver.

[This message has been edited by Ian (edited 23 September 2002).]
Reply With Quote
Old 27 May 2003
Registered Users
HUBB regular
Join Date: Nov 2002
Posts: 60
If the seals are old they scar easier. Sometimes some old mud (or similar) dries hard on the extreamities of the chrome fork legs and when you put the forks under compression this gunk is hard enough to get past the dust cover and slightly scrape the fork seal. It is possible to try and clean out any of this gunk that may have gotten caught under the seal lip using a tapered match by lifting the dust seal and pushing the match end (use a knife to taper the end first) between the seal and the fork leg and then pulling it around the full circumfrence. This is only sometimes going to stop the leak and then only for a while.

But first try releasing any excess pressure in the forks (as Ian said) before trying any of this!

It's fairly easy to change the seals (assuming you can get them) yourself if the leak persists. You can find a copy of the WP Extreme Workshop Manual on the net using www.google.com for a step by step guide. If in need ATF (automatic transmission fluid) can be used temporarily in the absence of proper fork oil.
Reply With Quote

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


NEW! HU 2015 Motorcycle Adventure Travel Calendar is now available! Get your copy now for some terrific travel inspiration!

HUGE, 11.5 x 16.5 inches, beautifully printed in Germany on top quality stock! Photos are the winning images from over 600 entries in the 9th Annual HU Photo Contest!

Horizons Unlimited 2015 Motorcycle Adventure Travel Calendar.

"The calendar is magnificent!"

"I just wanted to say how much I'm loving the new, larger calendar!"

We share the profit with the winning photographers. YOU could be in the HU Calendar too - enter here!

HU DVD Autumn Special!

Take 40% off Road Heroes Part 1 until October 31 only!

Road Heroes features tales of adventure, joy and sheer terror by veteran travellers Peter and Kay Forwood (193 countries two-up on a Harley); Dr. Greg Frazier (5 times RTW); Tiffany Coates (RTW solo female); and Rene Cormier (University of Gravel Roads).

The first in an exciting new series, Road Heroes features tales of adventure, joy and sheer terror by veteran travellers."Inspiring and hilarious!"

"I loved watching this DVD!"

"Lots of amazing stories and even more amazing photographs, it's great fun and very inspirational."

"Wonderful entertainment!"

Check it out at the HU Store! Remember to use Coupon Code 'HEROES' on your order when you checkout.

Scottoiler automatic chain oilers. The most important accessory for your next motorcycle adventure!

Renedian Adventures

Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!

What turns you on to motorcycle travel?

Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.

Books & DVDs


All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.

Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!

All times are GMT +1. The time now is 23:53.