MNSBR: Ktm Leaky Fork Seals - MNSBR

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Ktm Leaky Fork Seals

#1 User is offline   zxGran Icon

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Posted 10 February 2016 - 12:45 AM

Recently replaced the fork seals and bushings on KTM 250 and they leaked like hell when I rode last time. By leak I mean almost dripping (could feel the oil at the bottom of the forks after riding). After the ride, used the seal mate and that seemed to stop most of it. We will see when I get her out again.

Do you guys ever have a fresh set of seals leak for the first few rides or so (maybe the lips aren't sealed properly)? I'm fairly certain they are not upside down so let's assume that's not the issue

Bought the bike used and abused so I can't rule out dented forks etc. except that before only one seal leaked and now they are both about the same.
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#2 User is offline   Aprilian Icon

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Posted 10 February 2016 - 08:21 AM

did you grease the seal lips?
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#3 User is offline   TLRSKUNK Icon

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Posted 10 February 2016 - 08:43 AM

Did you buy "Leak Proof" brand aftermarket seals? or stock ones?
Did you grease them upon install? Torn seals during install is a very common issue.
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#4 User is offline   zxGran Icon

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Posted 10 February 2016 - 01:53 PM

I rubbed some fork oil around the lips of the seal, and used electrical tape over the lower ridge that holds the bushings to avoid damaging the seal as I slid it over.

I bought moose seals which I've used before without much issue
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#5 User is offline   JVS Icon

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Posted 10 February 2016 - 02:11 PM

No job in kyles garage is complete without electrical tape.
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#6 User is offline   zxGran Icon

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Posted 10 February 2016 - 02:12 PM

View PostJVS, on 10 February 2016 - 02:11 PM, said:

No job in kyles garage is complete without electrical tape.

You're damn straight
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Posted 10 February 2016 - 05:19 PM

oil and grease - no difference as long as it comes from a dead dinosaur

perfectly interchangeable with no impact to results, right? :bankhead: what weight grease do you use in your engine? :confused:
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#8 User is offline   zxGran Icon

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Posted 10 February 2016 - 05:40 PM

View PostAprilian, on 10 February 2016 - 05:19 PM, said:

oil and grease - no difference as long as it comes from a dead dinosaur

perfectly interchangeable with no impact to results, right? :bankhead: what weight grease do you use in your engine? :confused:

Good point, I probably should have used the same grease I use when putting my oil drain plugs back in. My bad
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#9 User is offline   JVS Icon

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Posted 10 February 2016 - 05:51 PM

Just mix some gorilla glue in the fork oil. Homemade stop leak. Boom.
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#10 User is offline   zxGran Icon

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Posted 18 February 2016 - 09:54 PM

Ok, so I'll admit I must have fucked up something. Both seals leak like JVS after watching gay porn.

To those knowledgeable, please edumacate me as to the proper way to do seals. I guess I need the pro tips since I can obviously change them, but messed up along the way. Examples include brands to look for, greasing, etc. I'm done messing around, just want to do it one more time and be done.

And no, I'm not taking it in
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#11 User is offline   JVS Icon

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Posted 18 February 2016 - 10:05 PM

From their website:

"If zip ties, duct tape or a hammer can't fix it we probably can't either"

-KylesGarage.com



Sounds like you should just take it in. Your good at that anyways.
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Posted 18 February 2016 - 10:50 PM

I had the exact same thing happen when I had a set in upside down, I would pull them and double check they aren't upside down.
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#13 User is offline   smokinsingle Icon

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Posted 19 February 2016 - 05:57 PM

If they are 48mm ditch the Moose triple lip and go with the green SKF seal from KTM, pn 48600969. Best seal by far.
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#14 User is offline   zxGran Icon

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Posted 19 February 2016 - 07:14 PM

View Postsmokinsingle, on 19 February 2016 - 05:57 PM, said:

If they are 48mm ditch the Moose triple lip and go with the green SKF seal from KTM, pn 48600969. Best seal by far.

Thanks for the tip, I'll look into it
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#15 User is offline   zxGran Icon

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Posted 24 February 2016 - 09:18 PM

Update, pulled the forks apart and upon inspection, realized the support rings for the outer tube bushings were bent on both forks (the angle looked like they were both supposed to be that way). If the bushings didn't seat, I wouldn't expect the seals to seat either so I think I found the issue.

Going to replace everything, bushings, seals, rings, etc with KTM kit and will update afterwards.
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