I'm having a similar issue with fork oil leaking, but its not a bad seal...its a significant pressure build up in the fork (rebound leg). I slide a thin plastic card between the seal and the fork to clean out what I thought was dirt, and a BUNCH of pressure was released. The seal appears to be fine, but over time I'm getting a significant pressure build up and the fork does not have a bleeder screw on top so eventually is has to escape somewhere. Anyone have any insight into what I should do?

 

I tried that first. I did have a bunch of air come out. But still have a leak. Just slower than it was. I must have has almost a 1/4 cup of oil come out on the first leak.

 

I would assume that. I'm hoping someone else will join in and see if they have a solution to the pressure build up. For me, I'm about 90% that I'm going to buy the Xplorer Pro 270mm suspension anyway. I'm not a fan of the stock. I ride almost exclusively in the dirt.

 

Just got word from the dealer that the fork seal kit is back ordered. Hoping for early September. But who knows. Frig.

If it happens to more people they will have to do something about it. Like recall and add a air bleed valve. Becomes a safety issue with control and oil on the pads.

 

Just found a puddle of oil on the ground after parking the bike in the garage for a week. I pried down the wiper seal and then used a fork seal scraper to clean under the fork seal. I did find a very small pice of debris on the seal tool and It seems to have stopped the leak. I couldn’t believe the pressure that came out of the fork. Also hope someone chimes in with some info on the pressure question?

 

They will build up pressure with temperature or altitude changes. Leaks are the result of dried dirt getting shoved up in the seal. Even a minute amount could manifest a leak, especially if there is an air pressure build up . I can modify the fork caps to add bleed screws. Its a relatively simple machining operation.

I believe I have some of the 43mm seals in stock if anyone needs them.

 

16 586 kms on my 22 Norden and both fork seals started leaking. HQ. Says no warranty I say its bullshit…

 

Do you sell the modified caps?

I do not. I would need your caps to modify. I see a lot of minute road grime that builds up on street/Adv forks that seems to kill fork seals. Usually it’s in the last inch or two of the travel. Had two sets in the last week that I had to scrub the grime off with a scrubbing sponge/steel wool. So inspect the chrome. Just because you’re not riding off-road doesn’t mean things aren’t getting dirty. I’ve had road race bikes that seals went bad due to rubber dust from sticky race tires on the chrome. The road grime seems totruly stick to chrome worse than regular dirt and mud.
this is from a Versys fork

 

Ok thanks. 16 500 Kim’s on the Norden and right seal is weeping. Cleaning them up now, the weather has been really hot here lately so I think the pressure is building up and forcing out oil.

 

So indeed I did have a buildup of crud similar but not as bad as your Versys pic there.
I removed the dust seal and cleaned out the oil seal and had a blast of pressurized oil shoot out all over. I cleaned the crud off the chrome and put everything back and after 3 days of riding there is no more leakage. Hoping it’s going to stay like that as the local dealer has no idea when a set of seals would arrive. Im starting to really despise HQ for their lack of the simplest maintenance parts for their bikes.
In the meantime, I would like to add a set of pressure relief valves to my caps. I am in BC Canada so sending off my caps is not such a great idea.
Do you have any advice on what or where to get the pressure relief valves?
thanks for any ideas…

 

I blew one riding hard in Colorado. Had about 3,800 miles on it. Was all over the radiator shroud by the time I got back.

Found an empty coke bottle, cut a 4" long pointed piece, slid it under the seal and all the way around.

Pulled out a little bit of dirt/mud and the leak stopped.

Will put shock sox and some green SKF seals on it when I respring it but it hasnt leaked yet and I am over 4,500 miles now

 

Hm, well my Expedition model blew a seal about two weeks ago. I thought it might work itself out but it didn't.

I tried a piece cut off at 2 l soda bottle that went up there seemingly but didn't do the job. Then I tried a fork seal tool.

You have to pop the dust seal off to make it work but it seemed to do the job. I noticed that I was cleaning it that almost immediately there was air pressure. I'm thinking that's why the seal actually blew out because it's pretty well covered.

The bike has 12k miles. I have previous experience with SuMo racing and commonly with WP forks you want to have the air pressure release valves on the forks. It was a factory accessory at the time but I'm sure there's others. It's a very simple spring loaded pressure release. There are T20 screws already there but not seeing that one in my tool kit.

Is anyone else having issue with the fork seals pumping up?

 

I’ve got a 24 Expedition, had the right/rebound fork seal leak 180miles from Fairbanks on the way back from Deadhorse. Bike had 5000kms on it. Back in Fairbanks I pulled the dust seal and cleaned out the seal with a flossing stick. Didn’t see any dirt but also didn’t get a lot of pressure either. The leak slowed drastically but never stopped. Had the seals replaced by the dealer when I got home. Husky paid for the parts and I ended up covering the labor. I’m ok with it as it gives me a chance to build a relationship with a dealer I didn’t buy the bike from. I’ll definitely be picking up a seal doctor though.

 

If you have the expedition with Xplor forks, you would be wise to install push button bleeds. They are about $30, but you can push them while you ride and can relieve pressure several times a day if you are riding tough stuff. If you are diligent at it, you will most likely never need fork seals until you decide to change oil.

 

Do you have a part # or a link for some? I was looking around but couldn’t find anything that would fit for sure.

 

Yep, +1 👍

 

For those of you who ride almost exclusively offroad, I put on a set of Xplor Pro's. OMG what a difference...but they are about $6500 so not a cheap date. But you can move them from bike to bike, so its a one time investment.

 

Crazy difference huh? The people that say their standard suspension is good enough obviously never tried the pro components.

 

Sorry I was looking for a part # or a link for the bleeds not the Xplor pro forks

 

Call Slavens Racing in Colorado Springs. They have them. Tell them your bike and they will ship you the right ones. Everyone there are real rides/racers. Extremely knowledgeable.

 

Also Xplor and Xplor pro have different bleeders. The pro’s have a large diameter thread

 

The Xplor suspension is very good. Its what on my Husky TE300. If I had that I would not have upgraded. I had apex. And yes, just like any good suspension, you need it set up for your weight, riding style, and what you ride. Carls Cycle in Boise did mine. And yes KYB is also very good…but that’s not a direct bolt in to a 901.

 

I have a 2023, 901 with the "cheap" suspension, and have had no issues. For me this bike is used primarily for off road trips, packing ultralight camping gear and fly fishing equipment into the mountains and occasional dirt rides around my house. I have ridden the bike pretty hard I figure and over some pretty challenging terrain. I am sure better suspension is better, but I have found the stock set up shockingly good and have not felt the need to upgrade, despite riding my friends Adventure R that is Pro equipped. I have a Super Tenere which suffered a catastrophic fork seal failure as some of you have described here, not a leak. On that bike it is common for dirt build up and water to pool near the bottom of the male slider, knowing this, I thread a towel through there and clean and apply some wax on them. Have seen some pretty new models actually experiencing corrosion. I will employ this practice on the Husky after reading this.

 

2024 Norden 901 expedition. Leaking fork, right side after 5500km. Husqvarna rejected the warranty case. Ok, I'll do it but it seems like a pattern already.

 

Is the seal leaking because of a materials or manufacturing failure, or did debris cause a tear in the seal? I can see why this would be a grey area in terms of warranty claims.

 

Sucks but it will turn out better if you do it yourself all you need is the seal driver and a couple of tools to get the cap apart

 

My Norden forks seals blew at 2025 miles, wasn’t happy.

 

Also helps to keep the slider clean

 

Mine started leaking at 2k miles, I replaced both with fresh oil on my 2020 standard Norden. It was amazing how dirty the oil was at 2k miles, seals are easy but I didn’t expect one to start leaking so quick