Hey Everyone

having a problem putting my front wheel on (first time doing this 2003 kdx 200) and thought i would see if anyone has any suggestions.

after getting the front axle in and lining up the gear housing i start to torque to the recommended 65 ft lbs. well i only get to about 20lbs before the axle and the gear housing start to turn together. there is nothing i can do to hold the housing in place properly. it seems the axle has pushed up against the gear housing so hard that it locks it in place with it. i have the service manual which doesn't have anything special about this so i am at a loss.

anyone had this problem??? thanks for the help


larry

Wish I could help, but I know someone on here can...Best of luck to you!

There is a tab on the fork that lines up with the gear housing. Is it lined up?

yes it is lined up until it gets somewhat tight. then it spins with the axle when turning it. it seems like it should stay in place while the axle rotates but it does not. maybe the axle was put on with too much torque before causing the wheel to fit tighter than it should. i might just tighten it down and cap the gear housing where ever it ends up???? thanks



larry

Larry have you loosened the 4 cap nuts on the right lower fork leg?

the front axle shoulh pretty much bottom out by hand and then only turn a few degree's from there to torque then torque the axle cap.

maybee dirty or bent axle?

yea pinch nuts are lossened and axle is clean and straight. i can tighten it by hand then when turning with a wrench it goes about a half of a turn and both the axle and housing start to move..

I think i am going to try to space the wheel out more, the tapered part of the axle seems like it is hitting the housing prematurely?? Hope I don't break anything, going on my first ride this weekend!

Thanks for all the suggestions!


larry

careful eye on the brake rotor though.
I really never torqued my front wheel I just tightened till it stoped and chinched the "pinch nuts" there is noway for the axle to loosen up when those "pinch nuts" are tight and as long as there was no play I'm happy

Larry I hope you got everything worked out on it. It is definately a nice weekend here.

Hey everyone, just incase someone has this happen to them again I thought I would let you know what happened. It looked like someone have over torqued the axles causing it to go to far through the fork and eventually lock the gear housing in place do to its shape (tapered at the gear housing portion). I took sr5bidders' advise and only tightened it about a quarter of a turn (well below 65ft lbs reccomended) and hit the pinch nuts at their torque. The axle stayed in place and worked great. Thanks for all your reply's and thanks bidder.


larry

Glad to help, how was the first ride?