crush washers.

Hi guys ( and gals), I knew I had forgotten to mention something when I did the final drive oil change. I came across crush washers on both the drain and the filling hole. I examined them and found them to be okay to re-use; but in other manuals ( ACE 750 ) they recommend replacing them. I guess this is another item that I will buy by the dozen next time I am at the dealership.

I have often re-used these two crush washers - 8mm - cost about $3each - not sure why they can not be re-used and re-used? Who re-uses and have you ever had a problem? My theory on re-use is tat the threads are so long that I will see a leak before I loose the bolt - but not too sure about this. Can you get a substitute crush washer at less cost somewhere? Where? I think the antifreeze drain also uses a crush washer - but different size.

This may be a UK/US spec thing but the washers on my 2001 model are flat copper (rather than what I would call a crush washer which I would expect to find on an exhaust system).
It may equally be a terminology thing where in the US a flat copper washer is described as crush due to it's ability to deform a little when under pressure.
Assuming this is a terminology thing,then the reason for renewing is that copper "work hardens" & with repeated use can crack due to the afore mentioned hardening.
The internal & surface stresses caused by "work Hardening" can be relieved by heating the washer/gasket uniformly to bright cherry red & then either plunging into cold water or allowing to fully cool naturally,this will anneal it back to it's original soft condition.
A good way to ensure uniform heating is to lay the washer/gasket on a thin sheet of brass & heat the sheet from underneath,this method was shown to me many years ago by a clockmaker when I was trying to re-use a copper cylinder head gasket on my Triumph Bonneville.

The Bern wrote:

This may be a UK/US spec thing but the washers on my 2001 model are flat copper (rather than what I would call a crush washer which I would expect to find on an exhaust system).

The 'crush' washers on my 2003 and 2008 SWings were silver in color and I don't think they were copper under that silver - but I never cut one apart to check in this. The only place that I have encountered a copper washer is under the allen bolt on the bottom of each front fork. I am guessing that Honda used a 'crush' washer on the final drive oil and antifreeze bolts to better seal against fluid loss at low torque values while maintaining bolt tightness; whereas the crush washers elsewhere (exhaust manifold/forks) are copper to deform so that misalignment will not stress the metal that the bolts are threaded into - IMHO.

The washers I have always been given for drain plugs on my Hondas appear to be aluminium and function the same way as a copper one but with no risk of electrolytic reactions on the alloy castings .. I believe they can also be annealed but I'm not sure it's worth it as they are pretty cheap.

Re-use them.No trouble