KTM Fork Leaks: Replace Lost Oil Without Removing Forks?

Warning: this method IS NOT perfect! But now I know how I can clean my fork oil seals AND replenish lost fork oil on the trail if need be.

With the help of the KTM Fork Doctor and Tusk Fork Cap tools, it's possible to clean seals, remove springs, and check/add fork oil with the forks and front wheel still on the bike.

Performed on my 2010 KTM EXC Champion's Edition, but same steps should apply to any model with the common WP 48mm USD Open Chamber forks (a.k.a WP 4860 MXMA PA), with or without preload adjusters.

For the 'right' way to do this job, I recommend you check out these videos too:

How To Rebuild Fork Seals on WP Open Chamber Forks with Spring Preload Adjuster (EXC 2008-1016, and many others)

How To Rebuild Fork Seals on WP 48MM Open Chamber Forks without Spring Preload Adjuster (EXC thru 2007, and many others)

How to Set WP KTM Husaberg Fork Oil Level

Here are the parts I used. I am NOT affiliated with any of these brands, nor with Rocky Mountain ATV/MC, but they've been good to me.

KTM FORK SEAL DOCTOR: p/n 78129994000
TUSK PIN-SPANNER FORK CAP WRENCH: p/n 14-k486
MAXIMA 5WT FORK OIL: p/n 54901

[dw]

Would you be able to replace the seals using this same method, without removing forks from the bike? Or would it be easier just pulling them off…. I’ve got a 25’ 300xc w/5hrs, R/S fork leaked maybe 1/4-1/2 qt of fluid.

[SledPemberton]

Going to try this soon. How long has it lasted for? Have you since changed your seals.