difficulty installing front axle

[howvood]

I recently removed the front wheel from my 83 R65 and had difficulty re-inserting the axle. It seemed to bind as the shoulder or larger diameter portion passed through the right fork end. As this happened I recalled a similar instance many years ago with my R60/5. Is there something more that I should know?

[lkchris]

Originally posted by howvood
I recently removed the front wheel from my 83 R65 and had difficulty re-inserting the axle. It seemed to bind as the shoulder or larger diameter portion passed through the right fork end. As this happened I recalled a similar instance many years ago with my R60/5. Is there something more that I should know?

As a wise mechanic I know says, it's not the axle nut that holds the wheel on, it's the pinch bolt(s).

Need to pry apart the split area a bit to get the axle in.

Don't install new fork seals by pounding them in with the slider bottom contacting the ground--this pounds the split shut on some models.

[rocketman]

Other thing to look into is that they (the fork legs) are not aligned properly, Any bend in one leg or the other can cause this as well as the fact that the holes are simply not aligned which means loosening the pinch bolts for the tripple tree. If the forks have not been rebuilt in the last 30-40K might consider doing this and testing the lower folks legs for bends etc. There are any number of good sites on how to do this properly and it can a make a very big improvement in handling.

RM

[howvood]

Thank you both for the replies. I did try using wedges in the split area but I think my problem is more in the alignment and I will check this further. Thank you, again.

[James.A]

Not being familiar with the R65, I have resisted offering an opinion until a few more knowledgable members responded. Having waited for a few responses, if it were MY bike, I'd try this....

1.. Make sure the axles and the holes in the legs are clean.
2.. hit them with WD40 or other light lubricant
3.. loosen, but don't remove, the fork brace
4.. try fitting the axle without the wheel in place. nice 'n easy, don't force it.
5 .. if step 4 is successful, tighten the fork brace and try to pull the axle.
6.. If the axle pulls out easily, you should be able to fit the wheel.
7.. If the axle is stuck, you have a fork alignment problem.
8.. If the disc brake caliper gives you trouble, pull it and re-install it after the wheel is fitted.
9.. Do not open the brake hydraulic system unless you know how to bleed the brake. The caliper can be let to dangle by the rubber hose for this proceedure.

If the legs wind up in a bind, you will experience an un-natural suspension travel and will want to follow Rocketmans recommendations for fork alignment. If you did not loosen the pinch bolts on the lower triple tree, the fork alignment should not have changed by removing the wheel. I used this proceedure when installing a /5 drum front on an R75/6 that originally carried a single disc. The stamped fork brace that goes with the single disc brake is less rigid than the /5 horse-shoe brace. It was helpful to allow the legs to float just a little bit when assembling the wheel and brake. This would also be a good time to change the fork oil and/or springs if desired.