Got whole front end powdered and took fork to local stealership to have them put all the guts back in they sent them back and they look good til I got home and realized they didnt put dustcaps on. After calling them they said they would slide into place then pop off bc of powder coating. Said I dont need them but I want them on it. Question is do I actually need them? And can I sand some of powder off so theyll go on or another solution anyone knows? Thx

 

When I did mine I had to sand the powder off the inside of the caps where they go over the slider. Could take some off the slider as well just care carful. I used a red scotch brite pad, good luck those things are a pita to get on

 

Just add a set of:
Gloss Black Billet Fork Slider Dust Covers-45800014
They look great I have a set on my Fat Bob...

 

Yes, I think you do need them if you don't want to prematurely wear out your fork seals and also possibly the bushings. If you can imagine all the crap that gets on those fork tubes and gets slid up and down over your seals, it's not hard to see what will happen.
Your dealer is giving you a load of BS because they failed to call you and let you know of the problem, then put it back together without talking to you first. True, you brought them the parts so they may have resented that, who knows.
Get new ones or knock off some of the pc that's causing the bad fit. If the dealer won't at least share the responsibility and help you fix it, find a new one or a good indie.

 

Had the same issue a few years back when I had a Streetbob. I had the lower legs pc'd and the dust caps would not go on. I removed the powder from the legs and the caps fit perfectly. I wrapped some tape on the leg to protect it and used a file to carefully remove the un needed powder.

 

they will pop on no problem! i like to use an old seal on top of the dust cap then use your driver, pops right on 1-2-3. your dealer forgot to put them on and are making bull **** excuses

 

That's a good trick to use the old seal on top of the cap to drive it on... Wish I woulda thought of that....