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Fork oil volume worry ...

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Blue_SV650S
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Joined: 27 Nov 2008
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PostPosted: 00:43 - 29 Jan 2010    Post subject: Fork oil volume worry ... Reply with quote
Changed the fork seals on my KTM today .... the forks are WP 0518V704

Now from what I can gather, the oil quantity should be ~830cc per leg. So I bought 2*1L bottles ... and went about the filling ... basically dropping the 830cc in each and then pumping up and down a bit, and letting settle .... even put cap back on a turned upside down and did the same ...

Long story short if I have the 800ml in, then with springs in, the forks hydraulic at about 10-15cm travel ...

After playing for a bit I took the springs out and measured the air gap ... each leg only took somewhere in the order of 400cc ... .... Confused ... now I admit I might not have got ALL the oil out in the strip, but 50% ... no way ... a bit concerned really ... oh and a bit p1ssed off I have got/used/contaminated 2 bottles not just the one that it seems was all I needed ..... Sad

Anyhoo, when measuring the air gap (springs out, fully compressed, dampers fully down), I pulled the rods in and out several times in the process and then let settle, the damper rods feel smooth as if they are well damping (and therefore full of oil) ...

These are USD forks ...

So what has gone wrong ideas!!?!?!?!!? Shocked
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sumpgard
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Joined: 20 Nov 2008
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PostPosted: 17:25 - 30 Jan 2010    Post subject: Reply with quote
far to much oil are they twin chamber fofks? if so 230ml in eatch leg after completely draining .
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Blue_SV650S
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PostPosted: 18:10 - 30 Jan 2010    Post subject: Reply with quote
sumpgard wrote:
far to much oil are they twin chamber fofks? if so 230ml in eatch leg after completely draining .


If you look on page 107 of this https://moto.tt.free.fr/explorer/KTM_Manual_engine_250_380_1999_2003_english.pdf

You will see the specs for my forks (WP 0518V704 - White Power ? Up Side Down 43 MA) ... it only gives a level there though ...

However, if you look on page 97 you will find the same basic "White Power ? Up Side Down 43 MA" forks (different actual code/variant thought), but with a oil quantity too .. namely ~835cc per leg ...

Thinking
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sumpgard
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PostPosted: 10:35 - 31 Jan 2010    Post subject: Reply with quote
ok had alook i thought they were off a newer model try filling them right to the top with the forks collapsed leave for about ten minuits then syringe out to a level of 150 ml i had the same problem on a kx this cured it hope this helps.
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Blue_SV650S
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Joined: 27 Nov 2008
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PostPosted: 18:44 - 31 Jan 2010    Post subject: Reply with quote
sumpgard wrote:
ok had alook i thought they were off a newer model try filling them right to the top with the forks collapsed leave for about ten minuits then syringe out to a level of 150 ml i had the same problem on a kx this cured it hope this helps.


That is essentially what I ended up doing ... ended up with ~800ml oil that had been sucked/tipped out .... Confused
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