Fork cap leaking

[Bigbird]

I have a 2002 400SX with the 48mm forks and the preload adjusting caps. The suspension was redone by a local suspension company whom I have used on several KTM's, and does a significant number of the KTM's in District 36.

A few rides ago, I noticed fork oil seeping out of the black adjuster knob on the right fork cap. I took both caps apart and noticed the O-ring didn't seem to be in the right location when comparing it to the schematic drawing in the KTM manual. It shows the O-ring placement above the adjuster that fits into the damping rod, but mine was located around the small damping rod in the fork leg below the adjuster. I left it there, and cleaned everything up, and the leak went away until this weekend. Now it is back. Does anyone have the correct order of these parts, and/or how the cap should be assembled to eliminate this leak?

Thanks

 

[WhiPit]

It's because they poured oil down in the cartridge rod - where it doesn't belong.

Beware of who you let work on your suspension.

 

[Jeremy Wilkey]

Originally posted by WhiPit
It's because they poured oil down in the cartridge rod - where it doesn't belong.

Beware of who you let work on your suspension.

So does that make me a hack... :p Now I know for sure why Ron Heben continues to blow me off.. I should have know.... :uh:

bigbird, the o-ring seems fine, thats where it should be but make sure you have that rod and needle ingaged.

BR,
Jer

 

[DEANSFASTWAY]

The newer Husky forks seem to havethat problem sometimes and sometimes the rebound adjuster mech spring/ball/detent gets all mangulated in the caps or it was just from some monkeys trying to find the perfect ride and getting a little ham fisted.

 

[Bigbird]

Thanks for the reply. I did make an adjustment on the fly at the last event. When I took my fork cap off yesterday, I noticed that the black adjuster knob was not seated in the detent. I think guys were right. 'Must be careful with those caps.

 

[WhiPit]

DOH!

 

[DEANSFASTWAY]

On those black plastic caps I knew a guy that stripped them out and for weeks he couldnt figure out how to adj the forkys . We got him some kind of trick alloy ones . The hardest part was pulling out the platic X part with a pick .