Boxerworks.com

Use some WD40 on them then slowly/gently pull them thru with needle nose pliers.

The EPCO exhausts used the welded on "clamp" It looks like it may be stainless steel. EPCO made S.S. systems. I have 38mm Epco headers on my 81 R100RT and they are NOT like that on the ends.

I wonder if some JB Weld carefully applied and shaped would work?

Is the bike new to you? Perhaps it has extra pre-load added to the forks.

I updated to the spring loaded valve body and wasnt told the plastic washer was different, There is only one valve washer listed on MAXBMW'S parts fiche and now it's not chamfered. Thanks for your time.

barryh, sounds like you got it figured out! Did you make any extra washers?

I have done every modification and service bulletin to my forks and I still have clunking. I have tried different fork oil grades, different springs plus the improved valve body with no change in noise. I wish I had an answer. Bike has 178k so I guess that's how its' going to be. I have owned it 20 ...

I have an 81 R100RT and converted the internal valve body parts to the later design (on the right ) Part # 15 are shims used to take any play out of the assembly during installation of the old style valve body. Do you have the parts that are circled in red? #18 "intermediate ring" was used...

DAZ was 73, we were in the Army together 69-74. Retired school teacher. Rode to many rallies together!

Just a note to say a long time friend and poster here has passed away due to a massive stroke.
DAZ, REST IN PEACE my friend!