I am trying to build an ultra-trick 2017 Kawasaki KX250F. I had the engine done, ordered a Pro Circuit pipe, had the frame powdercoated, designed all-new Decal Works graphics, bought SFS triple clamps and used all the left-over titanium bolts that would fit from my old Honda CRF250. The bike has been in the garage for two months, but the first time I rolled it out to ride it, oil started leaking by the fork lugs. I’ve seen leaking fork seals but never leaking fork lugs. What do you think this is?
The big clue to diagnosing your bike’s problem is when you said that you “used all the leftover titanium bolts” from your old bike. It is critically important that you always use the exact same-length fork guard bolts that came with your bike. If the leftover titanium fork guard bolts were longer than the stock 2017 Kawasaki KX250F bolts, then they could extend through the fork lug and hit against the fork tube, denting it. This not only damages the fork leg, it breaks the glued-and-screwed attachment system. Do not ride your bike until you have both fork legs checked by a qualified suspension mechanic. You will have to replace the fork legs if you have dented them.
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