fraggs

never could spell stanshion or is it stanshun anyway you get the idea

If i remember correctly (maybe not) you have remove everything you need to now you need to use the fork stansion (shiney bit) as a slide hammer to remove the fork seal (slide them in opposite direction until the seal comes out). the reason for this is on the bottom of the stansion is a bearing that will not pass the fork seal and will aid you in pulling it out. hope this helps (if i am wrong i am sure someone will point this out an correct me)

Short answer YES you have to take the forks off (not too hard to do though) . A word of caution!! some if not all bolts on the fork legs will have stuck (corroded solid) be VERY Carefull when removing not to snap them off , (the bolts and the casting on the fork legs) use loads of penetrating oil (wd40 ect)) even the use of a blow torch may help to warm up the fork leg to help ease the bolt out BE CAREFULL you have been warned!!

do you have origional barrel as you can split the top and bottom parts and put new top (key lock ect) on old bottom keeping the origional coloured wires

Have you changed the plug it could be braking down under load (my lc did it on a regular basis, changed plug ok for another 6000 miles)

When you find out the correct grade and quantity of oil you put it in the top of the fork leg where the big bolt was (you took it out to remove the springs) sorry dont know the correct grade or ammounts but am doing some dt125r ones myself soon so will let you know unless you find out first?

WITH A BIG HAMMER !!!!