Don't get any fork oil in the rebound adjuster hole (in the middle of the cartridge) or it will ooze out the rebound adjuster. This is different from Showa forks.

Here's a good video:

http://www.youtube.com/watch?v=glG3gUjxjEU&list=PLAE9D20040C48EC0A&index=2


I bought a 2nd set of suspension for my bike ($325 from the local bike yard for race tech'd forks and shock (AND 14mm triples). Spent a few more $$ on springs and now I've got a SM setup and a dirt setup.

 

It's pretty straight forward. I encourage measuring your air gap, especially if they have been resprung/valved, because it's easy to spill some when you're draining and you won't know exactly how much you got out.

 

I'm gonna be in the same boat as you. Assuming you have the same forks as I do, the 4860 MXMA, I found this handy service manual online. It's for a few previous years and goes further in depth than just changing the oil, but I found it a useful study guide. Also the LC4 index thread on advrider.com has good info. I've been getting my tools in order and planing on using Amsoil Shock Therapy 5 wt oil. Was also gonna replace my fork seals while I'm at it. They're not leaking but I figured might as well, since I'm that far into it. If anyone else has any other recommended parts to be replaced I'm all ears.

http://slorider.com/ktm/manuals/WP4860MXMA2003.pdf

 

In my opinion (and it's only an opinion) - I prefer the feel of well worn seals + bushings with fresh oil. If your seals aren't leaking I say don't replace them yet, just do an oil change.

Like Ash said- pull the springs and measure your oil level before pouring the oil out.


That being said, the newer SKF seals are really good (nice and slippery compared to the older seals). You can get the whole kit here (seals bushings crush washers orings) for $85:

http://173.74.246.25/munnracing/showproduct.cfm?id=1564

The kit is for the closed cartridge forks, but everything you need to do the open cartridge forks is in there, you just end up with a few unused o-rings.

 

mostly just want to save this link. that's a great price for all that stuff!

the youtube video posted is a pretty good how-to. your manual should tell you what oil weight and air gap to use.

 

I have the forks off the bike, but as I layed them down in the back of my truck they leaked out quite a bit. They seem to be leaking out of the rebound adjuster/knob... Any insight to this? I haven't done any work to them yet, just fyi.

I'm going to have to do some research on the internals of forks because I'm pretty ignorant to how the internals work.