HELP! 640 adventure front axle.

[Falcon Rust]

Hi,
anyone in the Coomera area, that could help me with my bike. I have bought a new rim and upon reinstalling it, the front axle has decided not to go back in. Yes, the forks are straight, and the bushings/ spacers are all in place. it's the axle on the right side (sitting on bike) that's bigger than the clamp and won't go it. i've tried to open the fork clamp with a screwdriver, and use a little bit of hammer. everything has been greased, but with no luck.

I really need help, my number is 0421 964 748. hope someone with more experience can shed some guiding light. i don't really know what else to do.

cheers,
Daniel

[D-Rally]

Did you buy a new rim or a complete wheel?

[Falcon Rust]

rim and wheel. but the axle slides fine in the wheel. it's the clamp that seems to have gone tighter.

[KevS69]

Originally Posted by Falcon Rust

rim and wheel. but the axle slides fine in the wheel. it's the clamp that seems to have gone tighter.

Does the axle slide in without the wheel fitted?

[Falcon Rust]

Hi,
the axle slides in the wheel but won't go into the bottom of the fork. the bigger part of the axle won't fit into the bottom clamp of the right fork. as if the fork clamp has shrunk or closed up, bike wasn't touched. anyway, i have cleaned and greased it all, but it still requires a lot of force to open the clamp and push the axle. it just requires a lot more force and i am worried to mess things up. i am not a pro mechanic.

slightly pissed off now.

Originally Posted by KevS69

Does the axle slide in without the wheel fitted?

[KevS69]

Just move the wheel out of the way for a sec, does the axle slide in with no wheel? no? very very gently tap a large flat screwdriver into the slot on the bottom to open up the hole slightly, does the axle slide in now?yes? leave the screw driver in place, pull the axle out & fit the wheel, read up on how to correctly align the forks? & never over tighten the clamp bolts, hope that helps

Originally Posted by Falcon Rust

Hi,
the axle slides in the wheel but won't go into the bottom of the fork. the bigger part of the axle won't fit into the bottom clamp of the right fork. as if the fork clamp has shrunk or closed up, bike wasn't touched. anyway, i have cleaned and greased it all, but it still requires a lot of force to open the clamp and push the axle. it just requires a lot more force and i am worried to mess things up. i am not a pro mechanic.

slightly pissed off now.

[Falcon Rust]

Kev,
i did that, it's still quite hard to push it in, i had to try using a hammer and a piece of wood, it's not moving much. really stiff. with the screwdriver it when in but it requires to be opened a lot more to go in. i hope i don't screw things up.

also, the gap is about 1-2mm when i open the fork clamp. quite unnerving.


Daniel

Originally Posted by KevS69

Just move the wheel out of the way for a sec, does the axle slide in with no wheel? no? very very gently tap a large flat screwdriver into the slot on the bottom to open up the hole slightly, does the axle slide in now?yes? leave the screw driver in place, pull the axle out & fit the wheel, read up on how to correctly align the forks? & never over tighten the clamp bolts, hope that helps

[Young-gun-640]

Originally Posted by Falcon Rust

Hi,
the axle slides in the wheel but won't go into the bottom of the fork. the bigger part of the axle won't fit into the bottom clamp of the right fork. as if the fork clamp has shrunk or closed up, bike wasn't touched. anyway, i have cleaned and greased it all, but it still requires a lot of force to open the clamp and push the axle. it just requires a lot more force and i am worried to mess things up. i am not a pro mechanic.

slightly pissed off now.

Maybe a dumb question, is the axle new as well? If it's your original axle, how long has the axle been out of the fork clamp for? Make sure the axle can slide through both forks without the wheel in between them, YOu might be catching a lip in the wheel thats stopping the axle sliding through that just so happens to coincide with the shoulder on the axle trying to enter the fork?

[minusone]

This can happen when a hammer is used and flares the axle.
Grind off the flaring and smooth it out

[overlandr]

Originally Posted by minusone

This can happen when a hammer is used and flares the axle.
Grind off the flaring and smooth it out

Maybe he used a hammer to remove it and it flared the end. I'd use fine emery cloth around both ends of the axle to highlight any high spots and then a fine file to gently remove those high spots.

[winna]

How'd you go mate, sort it out?

[Falcon Rust]

Haven't had any luck.

And it's the larger end that doesn't go in into the bottom right fork.
If anyone is around here I am happy to buy you some beer.

Originally Posted by winna

How'd you go mate, sort it out?

[Young-gun-640]

Originally Posted by Falcon Rust

Haven't had any luck.

And it's the larger end that doesn't go in into the bottom right fork.
If anyone is around here I am happy to buy you some beer.

What suburb are you in?

[Falcon Rust]

Upper Coomera
My number is 0421 964 738

Originally Posted by Young-gun-640

What suburb are you in?

[Falcon Rust]

Thanks to Poppy and Young Gun for your help. All it needed was a file and patience. I lack both.

Thanks again,
FR