I am installing some new suspension components an have run into a problem. Sometimes it's the little things that just F up our day.

So the little copper washer on the bottom of each fork leg, you know the one under the 6mm hex bolt. Well those suckers are stuck in there and I can't get them out. I have tried picking at them, moderate heat, lightly bouncing the fork leg on the floor all to no avail.

Any suggestions

If I can't get it out, what about just leaving it in there, any harm in that?

 

Is the damper rod out?

 

Yes the fork legs are completely disassembled

 

I would get them out and put in new. I just did 49mm forks and they didn't seem that stuck.
Should be able to get them out with the right pick.
Mine were grooved pretty good, I wouldn't trust them to seal.

 

Since you picked at them, chances are you nicked them so they most assuredly would not seal properly now anyway. Try taking something like an appropriately sized tapered flat blade screwdriver and gently tapping the blade into the hole so it grabs and then give it a little twist and pull action.

 

And you can find replacement copper washers at some auto parts stores. The HD copper washer is outrageously priced. (assuming they have it in stock...which one dealership didn't when I asked a long time ago during a fork oil change...)

I ended-up using the OEM original washers that was on the bike because they simply didn't look that bad and they have held just fine. I had spare copper washers in case they leaked, but they didn't and haven't.

I will say that mine were not hard at all to remove, just a nudge with my fingernail... but I had chrome lowers.

 

I forgot to mention that I have the Arlen Ness HotLeg forks, which is probably why I am having an issue with it. The hole where these things are, are almost the size of the washer and since it is copper it is smashed and expanded down in there.

So far I have not picked at bad enough to bugger it all up.

 

I would put it down for awhile. Clear your head, sometimes the BEST thing you can do. Spray a little wd-40 type stuff around it. Then I would pick from the middle hole out, not from the sides. Grind down the pick if you have to.

Hope it works out for you, Be Safe JIM

 

If it were me and they're not already gouged up, l I would just leave them in there. They're copper and made to deform. Shouldn't be a problem as long as you get the bolts back in there tight.

 

Fresh head and a tapered easy out, worked like a charm. Got finished with my Ohlins install. Now off to bed before I can't wake up for work tomorrow.

Only thing left is fender and wheel and off I go!