S2r1000 Front Axle will not slide through wheel!

[superkain]

Just got around to pulling the front wheel of the S2R.  The bike drives easily enough, and the wheel spins quite freely when on a front stand and in the bike.

I removed the axle nut, the calipers, and all 4 pinch bolts, and tried to pull the axle out, and it would not move. After 20 minutes or runner mallet, the back end of the right size screwdriver and levering it out on the far side using the hole in the drivers right side of the axle, I got it out. it fought me the whole way.  

Now, the axle will not slide back through the wheel. Nothing seems misshapen or wrong with either the axle or the wheel, but it just doesn't fit. it goes in less than 1/4 inch, and just stops.

Has anyone ever seen anything like this?

Thanks!

[Dirty Duc]

Pull the calipers.  They hate you.

[superkain]

Forgot to mention, I had the calipers also removed. edited original post to reflect this.

Now that the wheel and the axle are both separated from the bike, the axle will not slide back through the wheel.

[Dirty Duc]

When you say 1/4 inch, you mean into the fork or into the wheel?

[superkain]

When you say 1/4 inch, you mean into the fork or into the wheel?

Back in to the wheel, it passes fine through the fork.

[Dirty Duc]

This is your new-to-you S2R1K?

I've had issues when I didn't get things aligned exactly... what's the condition of everything (bearings and such-like)?

[superkain]

This is your new-to-you S2R1K?

I've had issues when I didn't get things aligned exactly... what's the condition of everything (bearings and such-like)?

Yes, sir. New to me.

I haven't checked any bearings, like I said, wheel spun fine and freely when in the bike.  No visible issues with the axle. 

I don't know that I ever looked closely inside the wheel of my old s2r (R.I.P.) but it seems like the first inch or so, the bearing, seems to be minutely <1mm smaller in diameter than the internal shaft. This is probably normal, but I just noticed as I was looking in there.

[Dirty Duc]

I PM'd you also.

Does the axle fit through the wheel when it is removed from the bike?

[superkain]

I PM'd you also.

Does the axle fit through the wheel when it is removed from the bike?

No, the axle does not fir through the wheel once both are separated from the bike. Damndest thing.

Replied to PM.

[Speeddog]

No, the axle does not fir through the wheel once both are separated from the bike. Damndest thing.

Replied to PM.

Most likely, axle has been ovaled by someone over-tightening the pinch bolts.

Insert the small end of the axle into the left lower from the outside, in the standard rotational orientation (through holes parallel to axis of fork leg), rotate axle 90 degrees, then snug down the pinch bolts.
Remove, and check axle for fit in the wheel bearing.
Repeat until axle fits through the wheel bearing.

Likely the large diameter end is also ovaled, use the same procedure, but just until you can rotate the axle to any orientation in the lower.

Then reassemble, and don't over-do it on the pinch bolts.

[BK_856er]

Speeddog has the answers, as usual.

BTDT.  This same thing used to happen to me on my M695.  I even went out and bought a new axle due to the squished one.  The new one got squished on first use.  Then I wised up and used the simple trick to "un-oval" it - good as new by careful measurement and easy-install test.  For my bike, I need to use the lower end of the torque spec to prevent the axle from getting squished and causing difficulty next time.  Yes, I have a new/calibrated CDI 1/4" torque wrench.  I also bought a special tool to help gently drive out the axle when necessary.

BK

[superkain]

This makes a lot of sense! The pinch bolts on the small side of the axle were way over tight.  I'll try this today and let you know how it goes!

Most likely, axle has been ovaled by someone over-tightening the pinch bolts.

Insert the small end of the axle into the left lower from the outside, in the standard rotational orientation (through holes parallel to axis of fork leg), rotate axle 90 degrees, then snug down the pinch bolts.
Remove, and check axle for fit in the wheel bearing.
Repeat until axle fits through the wheel bearing.

Likely the large diameter end is also ovaled, use the same procedure, but just until you can rotate the axle to any orientation in the lower.

Then reassemble, and don't over-do it on the pinch bolts.

[Nekkid Tim]

So glad this was posted and answered.  I'm usually pretty good at figuring these things out, but I was MYSTIFIED as to why my front axle on my ex-race 800SS and now track day 1000SS were so damned difficult to install and remove.  I, too, bought a new axle and it fits fine.  I'm no longer doing quick-change front wheel swaps (endurance racing the 800SS) so the pinch bolts are not so likely to get over-torqued as they were back then.   Will have to remember this in the future, though, with both my track day and my street 1000SS's.   Thanks again.

[superkain]

It Worked!

Totally stupefied this morning, when the axle slid right through the wheel after I re-pinched it.

Unbelievable!

Speeddog, thank you!

[ducpainter]

It Worked!

Totally stupefied this morning, when the axle slid right through the wheel after I re-pinched it.

Unbelievable!

Speeddog, thank you!

Before you reassemble make sure the axle also slides through both fork legs easily without the wheel in the mix. There can be slight differnces in lengths of tubes and fork lowers that can make things more difficult than if you make sure everything lines up