ktm tricks,for leaking for seals, Inverted or 50mm forks,air box cover, 4strk choke
To stop fork oil leaks on 50mm white power forks try the following:
remove fork and wrap three layers of masking tape around the chrome tube.Cut the end at an angle with the point toward the seal.
Work the tape into the fork seal turning the chrome tube at the same time. If dirt is the problem it will usually walk up the tapered
angle you cut on the tape and out and away from the seal.
The dust wiper needs to be slid up before doing this.
If the forks still leak and you must take them apart
the tension springs can be removed from the seal (new or old)
and tightened. Roll the springs off the seal and look close.
there is a pin end screwed into the box end of the spring.
The pin end is tapered like a pipe thread and can be unscrewed
by twisting the two in opposite directions where they meet.
Cut about a 1/4 inch off the box end and reconnect the two halves by first twisting in oposite directions and releasing to screw the pin end into the box end.
This trick can be done on inverted forks as well.
90% of the time the seals are ok and dont need to be replaced.
Do the same trick on the dust scraper springs.
Put small zip ties on the inside of the air box cover in front
of the little metal keepers on the zeus fastners.
trim them clean and that will be the end of loosing the fasteners.
Put a wide zip tie on the choke knob and run it through the hole in the gas tank on the 4 strokes. Cut it so it is flush with the outside of the tank and so you can get your fingers on and pull to activate.
This is allot easier than reaching under the tank.
Turn the trottle upside down and re route the cables behind the front numberplate and between the right fork leg and the steering stem and under the top clamp. This a very clean routing and I have
done this on all my 4 strokes. Plug the drain hole with a wrap of
electrical tape . It will now be facing up. This is a good route because the throttle housing is protected from crashes and or tree
branches etc. If your 4 stroke kick start lever snags when you ride
it can be tucked in by moving it forward a groove on the shaft.
The stop can also be filed down and it will tuck in nicely.;)
The oil screen on the bottom of the engine can be a bear to get out due to vibration. It helps to put a couple of wraps of teflon tape on the threads. Be carefull not to get any strings of tape into the motor. Teflon tape is mainly used for easy removal of pipe and machine threaded fasteners. Hope some of this is a help to you fellow KTM guys.
To stop fork oil leaks on 50mm white power forks try the following:
remove fork and wrap three layers of masking tape around the chrome tube.Cut the end at an angle with the point toward the seal.
Work the tape into the fork seal turning the chrome tube at the same time. If dirt is the problem it will usually walk up the tapered
angle you cut on the tape and out and away from the seal.
The dust wiper needs to be slid up before doing this.
If the forks still leak and you must take them apart
the tension springs can be removed from the seal (new or old)
and tightened. Roll the springs off the seal and look close.
there is a pin end screwed into the box end of the spring.
The pin end is tapered like a pipe thread and can be unscrewed
by twisting the two in opposite directions where they meet.
Cut about a 1/4 inch off the box end and reconnect the two halves by first twisting in oposite directions and releasing to screw the pin end into the box end.
This trick can be done on inverted forks as well.
90% of the time the seals are ok and dont need to be replaced.
Do the same trick on the dust scraper springs.
Put small zip ties on the inside of the air box cover in front
of the little metal keepers on the zeus fastners.
trim them clean and that will be the end of loosing the fasteners.
Put a wide zip tie on the choke knob and run it through the hole in the gas tank on the 4 strokes. Cut it so it is flush with the outside of the tank and so you can get your fingers on and pull to activate.
This is allot easier than reaching under the tank.
Turn the trottle upside down and re route the cables behind the front numberplate and between the right fork leg and the steering stem and under the top clamp. This a very clean routing and I have
done this on all my 4 strokes. Plug the drain hole with a wrap of
electrical tape . It will now be facing up. This is a good route because the throttle housing is protected from crashes and or tree
branches etc. If your 4 stroke kick start lever snags when you ride
it can be tucked in by moving it forward a groove on the shaft.
The stop can also be filed down and it will tuck in nicely.;)
The oil screen on the bottom of the engine can be a bear to get out due to vibration. It helps to put a couple of wraps of teflon tape on the threads. Be carefull not to get any strings of tape into the motor. Teflon tape is mainly used for easy removal of pipe and machine threaded fasteners. Hope some of this is a help to you fellow KTM guys.
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