I've rebuilt a few of these forks in my time, it is pretty straightforward to get them apart, the tricky part is if you need to refill the damper with fluid (depending in the damper), if it will indeed take/hold new fluid. The bushings are also tricky, but luckily I've not had to change any. I believe you need special tools for this job, or at least they are easier to change if you have them.
No on to the fork disassembly.
Undo the allen bolts at the bottom of the fork legs a few turns.
Knock with a mallet/hammer to release the damper shaft from the inside of the fork outer (you may need to repeat the above, loosening the fork bolt a few turns, then a gently tap with the mallet until the bolt moves)
You should now be able to pull the uppers from the lowers
Clean the inside of the lowers with a rag, then lube up the bushings inside them with some fork of suspension grease/judy butter
Clean the stantion outers and slide back together. Tighten up the bolts (not too much i.e. don't lean on a breaker bar) and that is that done.
If when you have got the forks apart you want to take out the damper, you'll need some circlip pliers. One leg contains a dummy rod, the other the damper. Once you have the circlip off, you may need to use something long down the stantion to tap the damper out.
I can't advise you on the damper refilling as I've not done it, but if you have a plastic bodied damper, and it has no oil, I believe it can be refilled, but you can't open the body of this one up, so a faff. Alu bodied dampers can be refilled more easily I believe.
The elastomers/springs are easy enough to sort out. Undo the crown bolts, then the plastic bolys/bits on the top of the crown (the black bits, not the adjusters), and tip the fork upside down - whatever inside should fall out unless it has perished in there (elastomers), and if so, use whatever you can to get it all out. Depending on the age, you could have elastomers on a skewer, or on the plastic 'jax' spacers. Or if you are lucky, they have been replaced with springs (solid one piece, or two piece affairs).
I think that's pretty much it in a nutshell, aside from when you stick the stantions bck in the lowers, grease the gap between the lowers and the seals (oh, and seals come off pretty easily using a screwdriver, or by hand if you are lucky).
Nearly forgot, no experience in repainting, but I've read powder coating not such a good idea on teh magnesium lowers, but in saying that, others have countered this and had it done without issue, others have ruined ther lowers. I'd go for paint to be safe.
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Last edited by ishaw on Thu Apr 19, 2012 8:19 pm, edited 1 time in total.