Evening everyone,

Sorry if this is in the wrong section, or has been covered before, but the internet connection where we are is taking an age to search through the forum.

We're currently in India and one of the XTs ('07 R) has developed a very slight leak in the right fork. It's not pouring down but is apparent higher up on the fork at the end of each day. Not too surprising given that we've just completed the KKH in Pakistan!

I initially assumed that it was a straight case of the seal having failed and me needing to find a new one but have since been advised to check that it is acutally the seal that has failed. So my questions are:

1. How do I check what is causing the leak?

2. What else could it be?

3. Once I know the size of the seal, will any seal that size do?

4. Should I stick with OEM parts (got quoted �60 for a pair in the UK) or try aftermarket ( offtheroad.de do a pair for �15)

Any advice you could give much appreciated!

So I can't help much but I am curious to know did yours cause uneven tyre wear?

My seal went on a long trip with alot of bumpy dirt, only did 8,000 km before it was stuffed. When I had the seals done the Yamaha shop said that if it wasn't a warranty job they would actually recommend a higher grade oil and better seal (non Yamaha) which was apparently cheaper and better suited to off road.

Got mine from OFF-THE -ROAD, allready lasting 30.000km.

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Saludos,
Joe
http://web538.ypsilon.ibone.ch/index...d=89&Itemid=42

neoprene fork protectors Acerbis / blue Puig wind shield / fork spacers 24mm / snorkel and resonater out / Acerbis hand protectors / 25 mm bar risers / 12 V outlet / "soft throttel mod" / engine protector home made / PC III USB / DNA ST2 / K&N ST 1 / BSM "Future extreme" exhaust / Wilbers "Adjustline" Shock / XTX links / luggage carrier home made / automatic chain oiler home made

[quote=Bobduro;140984]Evening everyone,

Sorry if this is in the wrong section, or has been covered before, but the internet connection where we are is taking an age to search through the forum.

We're currently in India and one of the XTs ('07 R) has developed a very slight leak in the right fork. It's not pouring down but is apparent higher up on the fork at the end of each day. Not too surprising given that we've just completed the KKH in Pakistan!

I initially assumed that it was a straight case of the seal having failed and me needing to find a new one but have since been advised to check that it is acutally the seal that has failed. So my questions are:

1. How do I check what is causing the leak? Check the fork tube for damage, impacts & scratches.

2. What else could it be? To much free play in the fork tube, poor quality seals, been over fulled with fork oil.

3. Once I know the size of the seal, will any seal that size do? Sorry don't have any sizes.

4. Should I stick with OEM parts (got quoted �60 for a pair in the UK) or try aftermarket ( offtheroad.de do a pair for €15) At those prices I would go after market.

Any advice you could give much appreciated

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Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
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My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

Had a similar problem happen just the RHS fork seal leaked. Took it to the mechanic and just said it hasnt completed failed but is weeping. No scratchs, dents or rust on the fork stanctions. Got the mechanic to replace the seal with an after market one but the fit just wasnt 100% and weeped a buit again, took it back and got a same make aftermarket one placed on and worked ever since.

Just check that the seal hasnt tryed to put up out of the top of the fork leg, i found one time mine was up about 2-3mm off the top of the fork leg and thats were it was leaking one time. Maybe i had a big impact or something and this tried to blow the seal but pushed it back in with fingers and stopped leaking.

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Plough on

Thanks guys, much appreciated.

We've ordered a set from 'off the road' and will get them sent out ahead of us. It's just weeping so will hopefully make it up to Nepal where we can replace with the new ones.

Woottonboy, I haven't noticed any tyre wear at all and only noticed the leak higher up on the fork leg as none is dripping down so...

FYI, our bikes have been, this leak aside, absolutely faultless on this trip, despite having been put through some pretty horrendous conditions, in fact, of all the overlanders (on hondas, BM's KTMs etc) we've bumped into we're the only ones to have not been delayed by any sort of mechanical or electrical problem. We really can't speak highly enough about the XT, and more than a few people have expressed admiration or jealousy! It really is the ideal overlanding machine!

We've got plenty of photos if anyone's bored at work.... just click here