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Is the long rebound adjuster rod (18" long skinny aluminum tube) supposed to have some sort of packing/grease in it? I blew out the rods with compressed air and some kind of nasty grease type stuff came out. Are they supposed to be sealed with something?

Mine didn't have any grease ('96 kx 250). Sounds like really old fork oil maybe?

That rod is the oil path up to the rebound adjustment clicker. Anything but fork oil in that would be bad, undesired, not good, down right naughty in the site of the Lord. This is yet another reason that all used parts bought without knowing the original owner should be thoroughly checked, like you are doing.

This stuff, was about an inch long, black and almost solid, it would mush like toothpaste. I can't imagine how fork oil would turn it to that (maybe left over junk from the manufacturing process?????), it does not surprise me though given the nastyness if the rest of the parts, but I am glad it is out of my forks now!

Re: 'This stuff, was about an inch long, black and almost solid, it would mush like toothpaste.'

barf!

I can't imagine what the forks felt like to the previous owner.

I am glad I only paid $33 for them on ebay, I would have been pissed if I paid $100+ for them. I will have about $75 (some used parts (fork caps), new bushings and seals, thanks Ryan, 5w Amsoil) into them by the time I get them back together. I think they will work fine, everything cleaned up nice with no mechanical damage inside.

I am going to use them as a tuning set to compliment my 2001's, I may end up selling them once I get the 2001's setup the way I want them.