Question about 2000 KTM SX 400 Racing

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2001 EXC 400 KTM how much oil should i put in the forks as they have leaked and replaced seals

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6ya6ya
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Posted on Jan 02, 2017

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  • 7 Answers

SOURCE: how to fill the front suspension on a ktm exc 2001

If you get the sevice manual or contact a dealer to get the correct oil amount for your bike, they need to know the model and year, you have to have the forks off the bike. take the fork caps off, take the springs out compress the upper fork tube all the way and add the specified oil. if they also give you the measured amount from the top that's the best way to get both fork oil levels exact. there is a special tool that you set the oil level in millimeters and it sucks out the oil to the right level, but before you do that step after adding the oil always pull and push on the cartage rod several times to remove air from the cartage tube. you will hear the air coming out and you will feel the changes in the cartage rod as the cartage tube fills up with oil and the air is removed.
something i'm confussed on though is if you replaced a seal you would have had to brake down the fork to replace it. you would have poored the oil into a container, cleaned all the internal parts,and used a fork seal driver to install the new seal. part of your question asks where do i put the oil in? thats in the open end of the fork after you have taken off the fork cap. It sounds to me like you only replaced the dust seal on one fork. that is not going to fix your leaking fork. you need to replace the oil seal thats pressed inside of the top fork tube.

Posted on Dec 26, 2008

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tabbycat282
  • 56 Answers

SOURCE: How much fork oil in a 2002 KTM 400 SX

White power allow a 110mm air gap with springs out and fork compressed as a general guide ,adjust from there according to prefrance . Thats probably,from memory about 600ml or so.If you overfill the leg ,cut the tip off the fork oil bottle , mark out on a clear piece of fuel hose 110 mm from one end of hose with a permanent marker, attach other end to the tip of the now empty fork oil bottle nipple, squeeze bottle,insert hose down to 110mm mark,take hand pressure off bottle and WWHHAAALLLAAA!!!!!!!!. Magically the excess oil is sucked back up into bottle.....Don't you just love the forces of nature. : ] ride on DB ......Hope this gets you out of trouble ....Flabbycat

Posted on Apr 17, 2009

  • 108 Answers

SOURCE: ktm output shaft oil seal

if you are lucky there is a clip behind the front sprocket remove both then pop the seal out drain gear box oil first though. if not which i think is most probable the engine will need splitting if you are good with spanners it is quite easy being a 2 stroke .in brief remove engine remove bore and carb in one lump remove sprocket gear lever split g-box .seal up push old seal out, from outside in, fit new then reverse prosses. a good manual will help.

Posted on Feb 13, 2010

dmsr63
  • 2050 Answers

SOURCE: fork seals leaking

I recommend sending them out, or get a factory manual. You need fork seal drivers (The correct size) and a solid mechanical background with some good tools. They ar not a simple deal. If you feel comfortable in trying it, get a good manual, and it will walk you through it.

Posted on Mar 25, 2010

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It's possible you may have leaked some oil, but first things first, clean the heck out of them and ride it around again to see if you are STILL leaking oil. If you have to top them up, there's a few methods out there, one guy I knew used a meter stick to measure the oil in the forks, but if you are going to be in there, you might as well drain the oil and start over with the correct amount of fluid. I hope this helps a little. Good luck.

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How to fill the front suspension on a ktm exc 2001


If you get the sevice manual or contact a dealer to get the correct oil amount for your bike, they need to know the model and year, you have to have the forks off the bike. take the fork caps off, take the springs out compress the upper fork tube all the way and add the specified oil. if they also give you the measured amount from the top that's the best way to get both fork oil levels exact. there is a special tool that you set the oil level in millimeters and it sucks out the oil to the right level, but before you do that step after adding the oil always pull and push on the cartage rod several times to remove air from the cartage tube. you will hear the air coming out and you will feel the changes in the cartage rod as the cartage tube fills up with oil and the air is removed.
something i'm confussed on though is if you replaced a seal you would have had to brake down the fork to replace it. you would have poored the oil into a container, cleaned all the internal parts,and used a fork seal driver to install the new seal. part of your question asks where do i put the oil in? thats in the open end of the fork after you have taken off the fork cap. It sounds to me like you only replaced the dust seal on one fork. that is not going to fix your leaking fork. you need to replace the oil seal thats pressed inside of the top fork tube.

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