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Old 04-28-2015, 10:43 PM   #1
EnduroJoe
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Any fork seal guru's out there?

I have a 2002 KTM 640 Enduro. right side is leaking in a perfect ring all the way around the tube. could the seal just be popped out? How difficult is it to service forks on my own.

I would appreciate any honest input..
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Old 04-28-2015, 11:12 PM   #2
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Old 04-28-2015, 11:31 PM   #3
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Google image search seal mate. Print, then trace on a flexible cutting board or coke bottle. Use per seal mate instructions. Bounce and wipe forks in 6 bounce intervals. If not clean by the 4th set, it's probably time to rebuild. Took me a few more bounces than that, but it worked.

Allballs sells inner and outer seal kits for cheap. Lots of sources for your stock weight fork oil. Will probably run you about $70 and take 1 1/2 hours (if it's your first time) to do it yourself if you replace seals.
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Old 04-29-2015, 12:38 AM   #4
EnduroJoe
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I have the seal mate, looks like I am going to attempt the rebuild. Thanks for the help.
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Old 04-29-2015, 09:53 AM   #5
Jae
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Not sure what configuration your forks are, but I've done a few sets of conventional telescopic fork seals and they were all pretty simple. I've yet to do a set of inverted, but that's mostly because I just don't have the spring compressor tool yet.
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Old 05-01-2015, 11:39 PM   #6
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Old 05-01-2015, 11:47 PM   #7
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I just made my own compression tool and the rest was easy.
but I still needed to buy a couple of fork specific items..

the specialty tools will be listed in the service manual with a part number.
plus the method will also be described.
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