I took a 1/2 day off of work yesterday to work on the bike, but ended up spending most of the afternoon just getting supplies and and a couple of tools (1-3/8" wrench I'll never use again). I finally got the forks out and disassembled. There's really not a lot inside of the older air suspension forks.
I replaced all of the bushings and seals. The one thing that struck me as odd, was the lack of dust seals on the forks. Maybe they didn't use them in 2000. Oh well, they're on there now.
The hardest part was getting the fork cap back on. The progressive springs are a bitch the compress with the cap while you're trying to turn it and engage the threads. I ended up going inside and I got my wife to hold the inner tube up while I did the rest. The sad part is that I had her in the kitchen, on her knees in front of me, and I didn't even take advantage of it.
I got the bike back together around midnight. I was on a mission. I rolled it out and played SQUID as I took it for a test ride. Work boots, shorts, t-shirt. Not even a helmet. Pathetic I know. It goes against everything I normally advocate.
The bike rides nice, and no leaks so far. I even rode to work today.