Any chance the forks are not as far down in the in the triples as possible?.. The compression of the forks during braking changes the geometry and aggravates existing problems ...
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I would use a cut off wheel on my grinder to get most the washer out of the way.... I would then use a pipe wrench on the bolt head.. Possibly wack the handle of the pipe wrench with a hammer... I have a small pipe wrench with very sharp teeth I try to reserve for tasks like this.. I think it 6...
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