Front Fork Rebuild: Oil Seals and Oil - KTM Duke 390 125 250 200

At some point you may need to replace the oil seals or change the oil in the front forks of your KTM Duke 390 125 200 250.   This requires a rebuild of the front forks.   Note that this is not a full service of the front forks as that requires rebuilding the cartridges.
I've blown one of the fork seals and I have a small oil leak so I need to strip the forks down and install new seals.  This also allows me to change the fork oil which since it still has the original oil is overdue for changing (although I can find no service interval specified for the fork oil).

Remember not to overheat the fork leg as this can weaken it, so a temperature gauge will be on my list of tools to buy, because I will be doing this again as I continue to practice my wheelies.

Fork Oil 450 ml SAE 4 per fork leg

Torque values:
Cartridge screw 25 Nm
Screw cap on outer tube 30 Nm
Screw Top Triple Clamp 15 Nm
Screw Bottom Triple Clamp 12 Nm

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