front wheel problems
 

Did a general clean of the bike today and then clean the brakes etc. Put everything back together and thought everything was ok. Went to move the bike to lock it up, front wheel locks up.... Basically theres not enough room between the discs and the forks for the brakes to get in and if I do force them in they just rub against the discs and hit them locking the wheel up. Any ideas to a solution would be much appreicated as I use my bike alot for work etc and want to fix this asap really.

Re: front wheel problems
 

Did you slacking the pinch bolt right of on the lhs fork if not it could cause the fork to pull in slightly when you tighten it up

Re: front wheel problems
 

Did you pull/nudge the brake lever with the calipers off the disc? It will cause the pads to close the gap a bit quite easily. Just pull the brake lever a few times with the calipers back on the disc and it should cure itself.

Re: front wheel problems
 

You may need to push the calliper pistons back, especially if the callipers are in need of a proper service.

Re: front wheel problems
 

Service the calipers if they're binding, save you replacing discs.

Re: front wheel problems
 

I dont think I explained my situation very well because im bit of tard lol. Basically if you look at the front wheel head on you can see alot of clearance between the fork and the brake disc for the caliper to fit, then when you look at the left fork theres barely no room for the caliper to fit. The brake pads are fine and the brake pads will fit on the disc its the actually bit where you screw the caliper mounting bits that wont fit because theres not enough room. Ive tried pushing the calipers back in but that didnt work and taking the front wheel off and have a look if anything was catching. Was fiddling the bike all day yesterday till late last night so didnt really get a chance to edit my post when i should have or address some of the replies.

Re: front wheel problems
 

Is it possible the left and right spacers have been mixed up? (can't remember if there is a spacer on both sides)

Re: front wheel problems
 

Im assuming when you say spacer your talking about the speed sensor? If thats the case then theres only 1 spacer

Re: front wheel problems
 

I must be thinking of the back wheel. There's a spacer on both sides of that

Re: front wheel problems
 

So what you are saying is the wheel doesn't look like is is aligned properly between the forks, you have a gap bigger on one side?

Is the axle tightened up to the correct torque setting?

Are all the spacers in position and the correct way around?

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.