Front Wheel Installation Problem

[r65lsk75c]

Ah, sometimes the simplest things seem to become so frustrating. I removed the front wheel of my '82 R65LS several months ago to completely rebuild the brake system including new rotors. I finally got the rotors mounted and attempted to install the wheel. After several unsuccessful attempts to get the axel through the hole in the left fork, I came to realize that the fork holes were no longer in alignment. The left fork is 1/8-1/4 inch lower than the right. I can raise the left by hand pressure against the bottome of the fork (significant spring resistance), but I didn't have enough hands to do this and get the axel through. Is this the preferred solution to the problem or should I loosen the right fork in the triple clamp and raise it to bring both forks in alignment? Can this be done easily?

Suggestions are appreciated.

Rick T :banghead

[flash412]

The proper thing to do is set the wheel aside and fix whatever is wrong with your forks. THEN install the wheel.

[PGlaves]

Well - either one leg is not extending as far as it should - or one is extending too far. While the latter is unlikely if that is the case something is broken and is decidedly dangerous. I wouldn't ride the bike until I understood what was wrong and fixed it.

I would remove the sliders. They are one bolt each to remove. Then determine why one damper rod is extending lower than the other. Probably an obstruction in one fork tube, which could be gunk or could be something broken and in the way.

Go from there!

[pmdave]

You might also take a close look at where the top of the tubes are held in the triple clamps. It's possible one tube could have slipped upward or the upper clamp (plate) could be bent.

A quick check is to loosen the "low" fork tube, wiggle it upward until the axle can be inserted freely, then see where the top of the tube is in relation to the other side.

If there is no obvious misalignment at the top, then it's time to dig into the internals. I assume you've got an overhaul manual, and perhaps some old ON articles to guide you.

pmdave

[Boxerkuh]

In the beginning I would not worry about the tire at all. Just work with the axle. I always slide the axle back through, just to make sure that what has haapened to you does not happen to me. Once you get the axle back through, I would double check the top of the triple tree and make sure that everything is tight and the way it is suppose to be. Then if everything is okay, I would remove the axle again and make sure that everything is still in place. On my rotors, I have to have one brake caliper removed to install the wheel/tire. In the event that the forks slide down when you removed the axle it appears to me that something is amiss internally. At which point you need to address that first and reinstall it. That is a bit of work.... :banghead However, it may have just gotton out of alignment.... (hopefully).
Good luck. :thumb

[r65lsk75c]

OK, it appears that I should investigate further my mis-aligning axel holes on the front forks of the '82 R65LS. The bike now stands patiently in the garage without a front wheel, fender, or brakes. My trusty manuals suggest that I can release the sliders by removing a bolt in the bottom of each slider. There may be a problem with the damper rod turning, but this apparently can be managed if I remove the plugs from the top of the forks and use a 13mm socket to hold the rods. Does this all sound correct? Would I be better served by removing the forks from the triple clamps and working with them on the bench?

I should note that the tops of the fork tubes are flush with the top of the triple clamp. I see no signs that one of the fork tubes has moved up or down. I did put serveral 100 miles on the bike this summer and really didn't experience anything that would suggest a problem with the front suspension.

So, if I am able to disassemble the forks, either on or off the bike, what should I be looking for as a cause for the mis-alignment? The only thing that comes to mind is a broken spring. Are there other possibilities?

Recommendations are certainly appreciated.

Rick T
'82 R65LS
'87 K75C
'75 Norton Commando
'74 Triumph Trident

[flash412]

... what should I be looking for as a cause for the mis-alignment? The only thing that comes to mind is a broken spring. Are there other possibilities?Quit worrying about it. Take it apart. I bet whatever is wrong will be pretty darned obvious once you have it apart.

[PGlaves]

Any followup available here? What did you find?

[r65lsk75c]

Disassembly of the forks was not too stressful, although it's probably a bit easier to remove the springs when the forks are still on the bike. The left fork produced a nasty mixture of fork oil and what appeared to be chunks of a black rubber-like substance. Taking the right fork apart revealed an intact hard black rubber donut on the damper rod. Looking at the parts diagram, this is called a stop ring. Amazingly, it is 1/4" in thickness. I suspect that this caused the misalignment in the axle holes. How it got pulverized, I haven't a clue. In any case, I have new parts on order including seals. Hopefully, everything will go together as designed.

Rick T :clap

[PGlaves]

Those rubber "bumpers" are known to deteriorate and fall apart after a number of years. Since the forks are not at full extension when the weight of the bike is on the wheel it often goes unnoticed. One bad one and one good one can put an unusual stress on the axle when the forks go to full extension right after a hefty bump, but in normal use this doesn't happen very often for most R65 riders. But as soon as you take the wheel off the lack of a solid bumper on one leg allows it to extend further. Replacing those bits should solve the problem.