THIS IS NOT A HOWTO This is more of a HOWDID. This post is merely things I noted while doing my first fork and headset service on my 2002 LC4 Adventure. I figure some of this info may be useful to others who are thinking of servicing their front end but haven't done it before. I have decent mechanical ability, but am far from an expert on the LC4. Suspension has always been taboo for me. I think it is because every suspension manual starts by emphasizing the cleanliness and organization of your work area. My work area is half of a garage filled with 2 motorcycles, too many bikes and various things that the previous renter has been "going to pick up" for a year now. Cleanliness and organization are its weak points. The same can probably be said about me. Well I finally bit the bullet and cleaned the garage. While I was at it I reorganized my tools so that everything I used would be in easy reach. The goal being that if it is as easy to put tools in their correct place as it is to lay them on the closest random horizontal surface, I might be able to cut out a large portion of my "where the heck did I put that" time. I had already done my "required reading" from the index. Required Reading - Fork oil change: Neduro's non-LC4 specific howto. Contains pretty much all you need to know to change your fork oil. Good discussion of how to measure oil height and a basic outline of the fork oil change process. Discusses some tips and tricks that make doing the job easier Steering Head Bearings - Required Reading: Laramies Guide to Drunken Steering head maintenance Discussion on steering head bearing adjustment To get in the right frame of mind I flipped through "How to Keep Your Volkswagen Alive: Step-by-Step Procedures for the Compleat Idiot" whose sage advice had taken me from the compleat idiot stage all the way through to a complete engine rebuild while in college. I put on some Tom Waits to set the mood. The notes I found an easy way to work on the fork was to use a small stool to hold it up and a zip tie around a nail pounded into the workbench. The inner nut on my fork was a 22. Not having a 22 box end, I first tried a large crescent but ended up buying a 22 and grinding it down to about 7mm thick to make things easier. Neduro describes simply pushing the damping rod down to remove the adjusting rod. This didn't work for me, but it was pretty easy to get it out. The threads describe filling with oil to 25 mm below the holes between the inner and outer tubes. My manual said to always keep the oil above the holes while pumping the damper so that is what I did. This brings to mind a key point. Even though each fork leg only takes 450mL of oil, it will take more than 1L of oil unless you pay attention and conserve your oil when adjusting the oil height After filling the first fork leg with oil and then pumping the damper to fill the damping chamber, you need to remove a significant amount of oil to set the oil at 120mm (or whatever you are setting your oil height to). I had poured a lot of oil into the drain pan before realizing I should be preserving it for the second leg. Even after squeezing oil out of my paper towels I came up short on the second leg and had to put it off till I could go get more oil. Would probably make sense to drain both fork legs first so that you can pour the overs from one leg right into the other. I found it useful to use my digital calipers as a dip stick to check oil height. I used a paper towel to absorb the last few mL and checked the height by setting the caliper to a little over my desired level and checking the oil height on the scale. I set it to 120mm from the top of the inner tube. The steering head bearings went really smoothly. Laramie tells you everything you need to know in his thread. I used special BMW grease for my headset. Hope that it doesn't have some sort of adverse reaction with my KTM. The only thing to note is that on my bike the ignition key on the top triple had some form of safety bolts that couldn't be undone. I just unplugged it from the wiring harness and left it attached to the triple the whole time. Make sure to take a good look at how all the wires and cables are routed before you start taking things apart. It'll make the reassembly go smoother. My first attempt at getting the whole thing together didn't go so well. I put the triple clamps on and then had a hard time lifting the fork legs through the clamps. My second attempt went much better. I assembled the whole fork away from the bike, tightened the lower triple a bit, removed the top triple and then lifted the whole thing into place. I finally found a use for that thing that KTM gave me in place of a seat. I settled the suspension by only tightening the large nut on the axle and pumping the forks up and down, then tightening the disk brake side and pumping the forks up and down before finally tightening the non-brake side. That's it. Big Thank you to Creeper, Nedura, Laramie and everybody else whose instructions and advice I followed in getting this done.