Re: front wheel problems
 

I take it you have you had the front wheel out?

If so, as someone else mentioned, your problem it is the little bit of tube that is clamped in the RH (LH if you are looking from the front) fork. Where the 'pinch' bolt is.

Basically, when the pinch bolt is undone, this little bit of tube should slide freely in and out (side to side) of the fork bottom. They tend to get a bit stuck/stiff. What has probably happened here is you knocked it out a bit when disassembling and when you have done the axle back up it hasn't slid back through. This means the fork will bend in when the axle is done right up.

So .... you need to free/grease up that little bit of tube re-assemble and you will be good to go!! 8)

Oh and only do the pinch bolt up AFTER the main axle is done up! ;)

Re: front wheel problems
 

when you say pinch bolt I take it your referring to the front axle clamp bolt? This bit of tubing you mentioned thats supposed to be in the forks I cant see it... now im either blind or its just not there....

and yes Dave I am tightening the axle to the correct torque settings etc

Re: front wheel problems
 

Ah you have a pointy ... they might be slightly different ... looks at microfiche ... http://fiche.ronayers.com/Index.cfm/...p/FRONT_DAMPER ... yep, no slidy tube bit by the looks ... so that isn't your problem, but if the fork bottom didn't slide over the axle bolt properly when you inserted it the same problem exists ... take a pic of the offending item ... I bet you have a fair bit of axle bolt still sticking out ;)

Re: front wheel problems
 

ermmm you have put the front wheel back on the right way round?

faling that did you take the calipers off?

Re: front wheel problems
 

You may have failed to align the speedo magnet castleations with the catlleations in the wheel, forcing the wheel over and locking it up. Don't try and move the wheel at all, just remove it again and, if you are very lucky the speedo magnet will have survived. Then when you reasemble make sure the castleations are properly aligned.

Re: front wheel problems
 

Well solved the problem last night eventually, gf's dad came around and had a look (hes a ex mechanic) and was doing basically the same thing I was until he realised there must be a spacer or something there to stop the fork from pulling inwards. Obviously there's no spacer for my model as its built in to the spindle according to the guy at the suzuki dealership I spoke with today. All we did was tigthen the axle up to the correct torque like we had been doing, now the fork has been pulled inwards, so he pulled it out a bit and held it there while I tigthend up the front axle clamp bolt. Job done

Bikes riding fine and its all good but it just doesnt make sense to me why if the spacer is built into the spindle the forks were pulling inwards when it was tightend. It just doesnt seem right that I have to pull the fork out then do the front axle clamp bolt out when isnt that the job of the spacer to stop the forks going inwards like that? is it just me or does that sound dodgy?

oh btw thnx for all the help :D

Re: front wheel problems
 

Aye, sounds weird. Sure it's a standard issue spindle?

Re: front wheel problems
 

Either your forks are bent or as I said, you need to lube up the bad boy ... even if you have undone the pinch bolt, it doesn't mean the forks will be extremely free on the spindle.