Got a Leak?

The Solution
Seal Savers are Lycra booties that wrap around the inner and outer fork
tubes.  They're designed to keep out the crud.  I've been using these on
the last five bikes I've owned, including my '99 KTM 300EXC with
conventional forks.

On my '99 EXC, I decided to combine the booties with fork boots as a
last-ditch effort to never again have leaky fork seals.  The booties went
on first, and then the challenge was to get the rubber fork boots
expanded around the booties.  Not an easy task, but three hands and a
couple sets of needle nose pliers made the job much more tolerable. I
put these on in April 2001 and didn't have a seal leak for the rest of the
time I owned the bike (sold it in May 2003). The Seal Savers allowed
some junk to get past the rubber fork boots (via holes from rocks,
sticks, crashes, etc.) without letting the seals get dirty.

On my '02 KTM 300MXC and both Kawasaki KX250's, fork booties were
pretty much the only solution. The good thing about upside-down forks
are that the water and crud tends to flow away from the seals, as
opposed to conventional forks where all the junk slides down the tubes
and comes to rest on the seals.

Here's an easier tip that might also help.  The round springs on the fork
and dust seals can be shortened, i.e. the diameter made smaller, to
make the seals tighter around the fork tubes.  Look closely at the
springs and you'll see where the ends are connected.  The ends screw
in together, so they can be unscrewed and separated.  Cut off a few
millimeters of the "female" end, screw the ends back together, put the
spring back on the seal, and you've now got a tighter seal.