How To Rebuild WP Xplor Forks

hey what's up everybody Dustin here with Rocky Mountain atv/mc and today I'll be showing you how to replace the fork seals on the WP Explorer for the [Music] Explorer Fork was new for 2017 it can be found on many KTM and Husqvarna dirt bikes now it's cool about these Forks is at the top here we've got a spring preload adjuster that's easily accessible and easy to use now the left fork is responsible for our compression dampening adjustment while the right fork is responsible for the rebound dampening adjustment now when it comes to rebuilding these Forks the process is going to beat the exact same for each fork so let's show you how to do it to do this job you will want to have some rubber gloves safety glasses rags and some contact cleaner as well as a forty eight millimeter fork seal driver forty eight millimeter fork seal bullet a pic flat head screw driver seventeen millimeter allen socket 3/8 inch drive ratchet 24 millimeter open-ended hand wrench as well as a 50 millimeter fork cap wrench and the tusk Explorer preload cap wrench now here we do have some replacement fork seals from tusk and we do carry many aftermarket and om options then we have some fork seal grease now the service manual does call for a four wait for coil however you can use any high quality five-way to fork oil then we've got a ratio right here as well as a drain pan to begin you will want to start out with some clean forks to avoid getting any dirt or debris inside of it during the rebuild process then you'll also want to lay out some racks so that you can lay out the parts as they are removed from the forks now the first thing we're going to want to do is record where our clicker adjuster is at to do this we're going to count the number of clicks as we turn it to the fully seated position which would be clockwise once we record that measurement we will then rebound the compression or rebound adjuster all the way out to the full soft position next you will want to make sure that the preload adjuster is at the full soft position next we can place the fork tube into our vise with soft jaws then we can take our fork cap wrench and crack loose the forecast now if you do not have a vise with soft jaw so you can still do this with the suspension mounted in the triple tree make sure that the lower tree is tight the upper tree clamp is loose then you can place your four cap wrench onto it and crack it free now we can remove the fork from the vise now I'm setting the fork tube on a bike stand so that you can see this we're gonna pull the outer fork tube down we're going to pull the spring down until we can access the lock nut there and place our 24 millimeter end wrench on to the lock nut then we can take our tusk preload cap wrench we're gonna place it onto the preload adjuster it will hold the lock nut the wrench that's on the lock nut in a fixed position and then we will break free the fork cap from the lock nut now this is important that we perform the process in this way and I'll explain that to you here in just a moment remove the cap the rest of the way then we can remove the fork spring then remove the adjuster rod then we can pour out the fork oil into our drain pan you will want to cycle the rod in and out several times to remove all of the fork oil now be sure to shake out the spring spacer it's now that we've got the spring and the adjuster rod removed from the suspension assembly I want to explain to you why it's so important to use the tusk Explorer preload cap wrench now on the fork cap as you can see we've got the preload adjuster that sits inside of the outer portion of the cap now when I rotate the preload adjuster you can see that it's connected down the center of the fork cap and the assembly rotates independently of the outer portion of fork cap now when this is installed on to the damper rod assembly the threads insert directly into the preload adjuster now if we were to try and remove the fork cap without using the tool we would put unnecessary pressure on the components that are inside of this inside of the preload adjuster and we can run the risk of damaging the components inside and we can place the bottom portion of our fork tube back into our vise with soft jaws next take your 17 millimeter allen socket we're going to remove the lower compression bolt now place a drain pan underneath this as when we remove this bolt you may lose some more oil then remove the damper rod assembly from the fork tube you want to bring your drain pan back up to your table then cycle the dampener rod several times to finish removing all of the oil then set it down on the table then we can remove the fork tube from our vise I'm going to place it on to our table and we can take our flat-head screwdriver we're going to wedge it in between the outer tube and the dust seal then with using a twisting motion we're gonna pry the dust seal away from the fork tubes body slide the dust seal down and out of the way then use your pick tool to remove the snap ring the next step is to remove the inner tube from the outer tube and to make things easier we're going to heat the portion of the outer tube or the oil so resides to approximately 50 degrees Celsius or 122 degrees Fahrenheit then we can slide hammer the inner tube out from the outer tube now it's going to take a considerable amount of force to do this so just kind of keep that in mind while you're doing this then we can remove the bushings and these seals from the inner fork tube now to do this we're going to take a flathead screwdriver we're going to place it into the gap on the bushing rotate our screw driver to open it like and remove it from the inner tube now as you remove these components you will want to lay them out in the order that they are removed then we can remove the other bushing stopper ring oil seal snap ring and dust seal with the forks disassembled clean and inspect all of the components now when it comes to inspecting your parts you want to pay special attention to your inner fork tube you want to be looking for any Nicks dents or scratches so take your fingernail run it along the length of the fork tube and anything that can catch your finger now has the potential to compromise your oil seal now if you do have any of those present you will want to use some scotch brite and/or emery cloth to buff it out now when it comes to inspecting your guide bushings the inner guide bushing as well as the outer guide bushing will have Teflon the outer guide bushing will have it on the inner diameter and the inner will have it on the outer diameter now you want to be inspecting the Teflon to make sure that there are no tears in it that it's not being worn through and the color of the metal is beginning to shine through or any metallic deposits if any of that isn't present on either one of the guide bushings you will want to replace them both now before we begin reassembly I just want to point out real quick that these seals are directional the dust seal is going to have a spring ring that will be facing the dirt side and this side with the shoulder will be facing up towards the oil now on the oil side the side that will be facing the oil will have a recess to it as well as a silver spring ring on the inside this again will face the oil now this side will have some insignia lettering or stamping this will face the dirt to begin the assembly we will first start by placing our seal bolt on to the inner fork tube now the reason why we place this on here is we have some sharp edges where the guide bushings sit and this will help to protect the inner diameter of the oil seals lips so that they don't get scratched so once we have that in place we're going to start by installing our dust seal but first need to take some grease we're going to coat the inside of it and we can slide the dust seal over the seal bullet and on to the fork tube followed by our snap ring then we can install our oil seal make sure to be mindful of its orientation and we're going to going to take some seal grease and apply it to the inner diameter of the seal now this is important to do it will one help to prevent stiction as well as aid and the installation of the seal on to the fork tube then it can remove our seal bullet we can install our stopper ring and we can install the outer tubes guide bushing then install the inner tubes guide bushing and again you will want to pull this open just ever so slightly so that it will fit on to the fork tube and slide it into place next we can install the inner tube into the outer fork tube then we can let the outer guide bushing drop into place as well as the stopper ring then we will use our fork seal driver to aid in seeding the guide bushing along with the stopper ring and then before we install our oil seal we're going to take just a little bit of the seal grease and lightly coat the outer diameter we can set it into place and we will take our fork seal driver that is a 48 millimeter and we will use this to drive the fork seal into its position now as you begin to drive the fork seal into position once it is seated once it's fully seated you will hear a change in the audible pitch now lets us know that our fork seal is fully seated now you also want to look down inside of here to make sure that you can see the ring landing for the snap ring to make sure that it is fully accessible then we can bring down our snap ring and set it into position you can either use the fork seal driver to set it into position or you can use the pick tool to make sure that it seats into its ring landing you should hear it snap into position once it's been seated go ahead and give it a good inspection to make sure it's fully seated into its groove next we can move on to installing the dust seal now before we see this we're going to take a little bit of seal grease and lightly coat the outer diameter of our dust seal this will also aid in the installation process now we're going to slide this down and then we can seat it with just our fingertips then we can take our fork we're gonna place it back into the vise with soft jaws the lower section here for the axle insert the damper rod into the fork tube now you'll want to place your finger on the bottom here to make sure that the damper rod fully seats into its final position you may have to turn or rotate the damper rod a couple times until you can find the right spot then you should see these threads come down and see it against the bottom part of our fork then we can install the forks lower compression Bolt and torque to 25.8 foot-pounds then we can remove the fork from our vise now we're going to fill up the fork with 20.6 two fluid ounces of fork oil now that's what this machine calls for in the service manual but when it comes to you and your machine suspension always be sure to reference the service manual for your fluid specifications then we can grab the damper rod and we need to cycle it several times so that we can bleed the air from the system now you can feel it in the dampening rod when you're cycling it when you encounter air it will just begin to start moving fast and instead of a dampening motion and you'll want to repeat this process again till you have very smooth dampened operation of the shaft being cycled so that all the air is removed now that we're finished with bleeding of the dampening rod we can go ahead and finish the assembly next we can install the spring baiser the adjuster rod make sure that it's seated inside of there now before we install the spring we're going to hold on to the damper rod itself then we're going to take the lock nut assembly we're going to rotate it clockwise or tighten it bring it down on the threads about one turn and what this is going to do is it's going to create a gap once our four cap is installed now we need to have the four cap completely installed and bottom down on to this part of the damper rod and then we will bring the lock nut up to four cap install the spring now this part might be a little bit tricky we need to be able to pull down on the spring hold on to the damper rod assembly then we're going to thread on the fork cap now when you throw it on the fork cap you want to thread it on by using the preload adjuster as that's what makes direct contact with the dampening rod you'll just want to lightly seat it against the rod then we can pull the spring down replace our 24 millimeter wrench onto our lock nut then we're going to rotate the lock nut counterclockwise while holding on to the spring preload adjuster and we're going to bring the lock nut up to the bottom of the fork cap once you feel it seat we'll take our tusk Explorer preload cap wrench place it onto the fork cap on the preload adjuster then we're going to tighten this to eighteen point four foot-pounds then we can bring up the outer tube we're going to thread it on to our fork cap and we can place this back into our vise with soft jaws then we can take our 50 millimeter fork cap wrench we're going to torque the four cap to 29.5 foot-pounds lastly we need to set our clickers back to their original positions to do this you'll rotate it clockwise till it's fully seated and then you will back it out to the number of clicks that we record earlier now that we're done with this fork we can move on to the next and repeat the exact same process and that's it it's really easy to replace the fork seals on the WP Explorer fork now if you have any questions as to what we've done here today feel free to leave us a comment below and we can get an answer back to you and don't forget to subscribe to our YouTube channel for more product spotlights how-tos and top fives and also see our website at rockymountainatvmc.com where we carry the largest selection of parts apparel and accessories for your motorcycle ATV and side-by-side I'm Dustin with rocky mountain thanks for watching and keep the wrenches turning [Music] [Music] you

Channel: Rocky Mountain ATV MC

Views: 83,595

Rating: 4.9209485 out of 5

Keywords: Rocky Mountain ATV/MC, rmatv, rmatvmc, atv/mc, atvmc, motocross, rockymountain, dirt bike, utv, atv, motorcycle, parts, accessories, rocky, mountain, wp, xplor, xplorer, fork, forks, front froks, suspension, rebuild, fork seal, dust seals, leaky seals, leaking, how to, how-to, replace, install, installation, ktm, fork cap, wrenches, tools, husqvarna, husky, sx, xc, xcw, tc, tx, te, fe, fx, fc, 450, 250, 300, 125, 501, fork seals, explor, explore

Id: EvdnbqN7auE

Length: 16min 24sec (984 seconds)

Published: Tue Nov 07 2017