HELP! 640 adventure front axle.

Discussion in 'Australia' started by Falcon Rust, Jan 17, 2013.

  1. Falcon Rust

    Falcon Rust Adventurer

    Joined:
    Jun 13, 2006
    Oddometer:
    96
    Location:
    Brisbane, QLD
    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
    #1
  2. D-Rally

    D-Rally Adventurer

    Joined:
    Feb 20, 2010
    Oddometer:
    51
    Location:
    Central West
    Did you buy a new rim or a complete wheel?
    #2
  3. Falcon Rust

    Falcon Rust Adventurer

    Joined:
    Jun 13, 2006
    Oddometer:
    96
    Location:
    Brisbane, QLD
    rim and wheel. but the axle slides fine in the wheel. it's the clamp that seems to have gone tighter.
    #3
  4. KevS69

    KevS69 Been here awhile

    Joined:
    Feb 19, 2009
    Oddometer:
    462
    Location:
    Adelaide
    Does the axle slide in without the wheel fitted?
    #4
  5. Falcon Rust

    Falcon Rust Adventurer

    Joined:
    Jun 13, 2006
    Oddometer:
    96
    Location:
    Brisbane, QLD
    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.





    #5
  6. KevS69

    KevS69 Been here awhile

    Joined:
    Feb 19, 2009
    Oddometer:
    462
    Location:
    Adelaide
    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

    #6
  7. Falcon Rust

    Falcon Rust Adventurer

    Joined:
    Jun 13, 2006
    Oddometer:
    96
    Location:
    Brisbane, QLD
    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


    #7
  8. Young-Gun

    Young-Gun KTM Tragic

    Joined:
    Dec 6, 2005
    Oddometer:
    1,225
    Location:
    Brisbane, Australia
    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?
    #8
  9. minusone

    minusone Long timer

    Joined:
    Nov 15, 2005
    Oddometer:
    1,297
    Location:
    Northern Beaches Sydney Australia
    This can happen when a hammer is used and flares the axle.
    Grind off the flaring and smooth it out
    #9
  10. overlandr

    overlandr Dystopist

    Joined:
    Nov 30, 2003
    Oddometer:
    5,929
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    Sydney
    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.
    #10
  11. winna

    winna Rallye bikes rule

    Joined:
    Apr 27, 2009
    Oddometer:
    226
    Location:
    Gold Coast
    How'd you go mate, sort it out?
    #11
  12. Falcon Rust

    Falcon Rust Adventurer

    Joined:
    Jun 13, 2006
    Oddometer:
    96
    Location:
    Brisbane, QLD
    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.

    #12
  13. Young-Gun

    Young-Gun KTM Tragic

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    What suburb are you in?
    #13
  14. Falcon Rust

    Falcon Rust Adventurer

    Joined:
    Jun 13, 2006
    Oddometer:
    96
    Location:
    Brisbane, QLD
    Upper Coomera
    My number is 0421 964 738


    #14
  15. Falcon Rust

    Falcon Rust Adventurer

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    Jun 13, 2006
    Oddometer:
    96
    Location:
    Brisbane, QLD
    Thanks to Poppy and Young Gun for your help. All it needed was a file and patience. I lack both.

    Thanks again,
    FR
    #15