New old bike: '85 NH 650
Well, I got the forks sorted. The circlips were so rusted that the ends broke off when I squeezed the pin pliers. I was able to use a mechanic's pick to get the right side off, but had to use a torch on the left to get enough slack to get the pick behind the circlip. That one had been over pressured a lot, going from the way the seal was bulged out. Anyway, the inside was really old, dirty oil. I cleaned everything inside and out with degreaser and brake parts cleaner. Luckily, nothing was rusted, and everything was straight. I made spacers twice as long as stock (2" vs 1") to up the preload. I hope to eliminate the need for air, or at least keep it very low. That makes putting the top caps back on interesting, to say the least.
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