Help...RM125X Fork Issues

[Cabmkr]

     I have rebuilt the forks in my RM125X project and there is a "clunking" on both compression and rebound. Forks are off the bike, new seals and 10wt fork oil 190mm level compressed. Everything looks in place and I even took apart a set of 38mm YZ125 forks for comparision. When I turn the forks upsidedown and compress the clunk stops. Kind of baffeled on this as everything is tights and as I believe it should be.  Both do the same thing and there is a slight stiction when it clunks. How loose should the washer be in the lower part of the fork tube?

[RMJJ]

I've had loads like that, it won't do any harm. What do you mean by the washer in the lower fork leg?
I'm going to guess you mean the ring above the top bush but underneath the oil seal.
It can go in either way but I bet you ask because is "dished"
The clunk and stiction is the bush moving up and down.

You can either hammer the ring flat, press it flat or buy new but it'll still do it to a certain degree.
I have had two nos complete sets of forks and they did it.
It's just manufacturing intolerances On new stuff.

Sometimes you can feel and hear it as a big clunk and sometimes you can't hear it but can feel it.
Don't worry about it, it's not abnormal, flatten the rings,
That's just how they are, they will still work, they won't break and will be safe.

[Cabmkr]

John,
    Thanks for the info, the ring I was talking about is the bushing or washer that the damper rod goes through on the bottom of the inner fork tube. If its nothing to worry about thats great but I have to admit my Yamaha forks don't seam to do it 

Thanks, Chris

[RMJJ]

Ok I know what you mean now, I've often wondered the same thing.
Some are tight some are loose on both used and NOS
I don't think it matters but don't actually know