there is an oil breather from the powervalve, so there must be some minor leakage through there - in fact i remember seeing my breather pipe smoke when cold. From the factory they used to fold the breather pipe over and ziptie it but i think that was just to avoid oil dripping on the trails...
it was quick thinking by motocrosscenter. these used to be hosted on the gasgas website, but when ktm bought them they removed all references to the legacy gassers
https://www.motocrosscenter.com/shop/en/content/8-gas-gas-parts-manuals
that is about the closest you will get to a workshop manual. owners manual and parts diagram
hyde developments used to make a disk guard that incorporated the bottom of the fork and then also a fork guard on the RHS, but it isn't pretty.
I am sure that bulletproof or one of the other aluminum guard manufacturers make something as well
can't you just get some rawl bolts (anchor bolts) to fit in there? I found them much better than stock handguard bolts and less effort than threading the bars
i'm pretty sure that once yopu have the slide out (think the float bowl plug has to come out to allow you to rotate it enough) then you can pull it out, may have to soften the rubber boots a bit with a hair dryer. It was never fun!
why do you need to remove it? I used to loosen bolts, remove bowl bolt then rotate it the direction i need to either remove slide and pin or replace jets through the bowl nut. I never did anything more significant than that
(don't think you can rotate the carb without taking the bowl nut or...
The 48 sachs forks were ok at best. I spent a lot of time trying to get them right, but it was always a case of getting one situation working fine and the rest not. As mentioned i purchased some kyb sss from a yz, skimmed a bit off the top tripple only, and then used everything else gasgas...
I went from 48 Sachs to KYB SSS and only had about 1mm shaved of my top triple clamp. measure your existing forks, and see if there is enough meat on the existing clamps to have them machined thinner.
I also had a yz axle and wheel spacer machined to match my GG hub as i did not have a yz wheel
with the short suspension travel it was like doing 10,000 squats on the whooped out track. I ended up spending most of my day testing all the ktm's and huskies
I did a berm buster on my trials bike and it is not really my cup of tea, graded forest roads with the odd more technical breakout single trail, I always liked the rocky stuff, Which is partly why i enjoy trials. I also tried Knaeves ville out near thames and that was hard, but mostly clay mud...