Join Date: Jul 2006
Location: Fairfield , Nor Cal,
Thank the internetz, the web gods...whom ever you pray to if you're religious for Shazaam, the hall of wisdom and this forum.
I recently removed my forks and took them to a specialist for rebuild. I noted when I removed the front wheel that the axle was pretty difficult to remove. I got my forks back yesterday and after installing them in the triple clamps and torquing all the bolts I got back to the wheel and axle.
I had a very difficult time sliding the axle even part way in to the fork tube lower, much less the wheel bearing. I deduced that the axle had been struck by something during a previous disassembly or reassembly.
After thoroughly examining the axle, I could see where the shape of the hole in the fork tube lower had been impressed into the metal. Hmmmm.....pinch bolts must have been over tightened at some point also.
After going through the hall of wisdom, I happened upon this post and voila' everything is explained. I read through Shazaam's post about the proper torque and assembly sequence and everything became clear.
I fished out the axle tool from the tool kit and found THAT was what had been used to drive the axle either in, or out or both. It was mushroomed on both ends and would no longer fit into the axle.
I managed to correct the deformed axle with a mill file and a very delicate touch. It will now at least slide in and out of the wheel bearing and the fork tube lower. The tool on the other hand, I did not have nearly the same success with, and will likely have to either find a new one or go back at it further at a later date with a mill file. Or maybe find someone with a lathe.
About the only thing I didn't do was grease the axle up on install. Someone previous to my ownership applied liberal amounts of white lithium grease that had hardened up and gotten sticky. I got so much WD40 on the axle and the wheel bearing bores cleaning that out that I decided to just skip the grease for now.
In the end, I got it all done, and didn't have too much difficulty mostly due to reading this thread first. So, as I stated at the beginning, Thank You. Thank You Shazaam, as always, your sage advice is worth more than the words I can type on this page. If I'm ever down in the San Diego area again, I owe you a beer at the very least..............sean
My garage: Twins:2000.5 Mille R, 2000 996, 1994 EX500 basket case 1993 900SS. Suzukis: 2004 GSXR600, 1992 GSXR750 oil boiler, 1983 XN-85 Turbo