Fork seals - How to

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DaveT

Race Dog
Joined
Jul 7, 2010
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Location
Somerset West
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KTM 790 Adventure R
Ok, since I decided to change this myself and the link at f650 does not work anymore. I will share my experience with fellow dogs.

You'll need:
- Fork seals x 2.  (duhh) Replace both at one time and not only one
- Hacksaw
- 10mm socket/ring spanner
- 45 Torx
- Allen key H8
- Allen key H7
- 2 x 600mL W10 Fork oil (2 x 550mL for Dakar)
- Rubber hammer (my preferred choice, if your aim is bad there is less damage ;D)
- Piece of solid wood

Procedure:

- Remove front wheel and brake caliper (45 Torx, Allen key H8)
- Loosen the bolts of the triple clamp and at the top of the fork ( x1)
- Let the fork drop out and remove the fork bridge so that the two telescopes can be handled individually.
- Hold one of the telescopes over a collection sump for oil and remove the 10mm bolt with the copper washer. (It will most likely be
 under a little pressure so be careful)
- You can pump the chrome section to get the oil out.
- When most of the oil is out remove the bolt at the bottom of the telescope that holds the spring and other thingies in place.
 

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