So, this idiot picked up a wrench without supervision.... - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 11 Old 04-08-2008, 08:55 PM Thread Starter
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So, this idiot picked up a wrench without supervision....

I knew better but did it anyway. I needed a new tube in my front tire and was smart enough to know I have no business playing with the tire levers I got with the bike but I was dumb enough to take off the front wheel. I took the wheel down to the local shop and just figure I'd reverse the process to put the wheel on again. Problem is, after getting it back on, the brake pads rub the rotor. What did I not do right?

Second question, should there be a torque setting for the castle nut? The guy at the shop said that it should be loose and that the cotter pin keeps it from coming off. I sure had to put a lot of force on the wrench to get this "Loose" nut off, is he wrong or was my bike put together wrong?

I appreciate the replies, my first thought was to ride it and see if the caliper settled in, but I don't want to make anything worse which is my usual way.
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post #2 of 11 Old 04-08-2008, 09:12 PM
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Are you sure you put the spacers back on correctly? The axle nut should be tight. Are you sure you have the rotor between the two pads? Can you post pictures of the rotor and caliper and the spacers on the wheels? Go to bike bandit and look at their parts diagram http://www.bikebandit.com/houseofmot...a-1994/o/m3689

94 KLR,tank guards,sw motech centerstand,Doo done, african switch,mirror dampners, powerpegz, twisted throttle fuses, aluminum skidplate, Bigcee shark disc and jug holder and subframe upgrade, progrip grips,maier handguards/brushguards, avon distanzias,fmf q4 exhaust, headlight guard, handlebar risers, billet rear brake reservoir bracket and guard, dual star shifter,garmin 2820 gps, tmod,disc cover, pcv mod,corbin flat

Last edited by Paulo888; 04-08-2008 at 09:15 PM.
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post #3 of 11 Old 04-08-2008, 09:31 PM Thread Starter
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There were no spacers that I'm aware of, I just slid the rotor back between the pads. I'll try to get a picture of it.
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post #4 of 11 Old 04-08-2008, 09:37 PM
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Front axle bolt torqued to 58 foot pounds. Back the nut off a bit if you need to align a hole for the cotter pin.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #5 of 11 Old 04-08-2008, 09:39 PM
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There is a spacer that goes between the wheel and the fork. Also did you correctly align the slots for the speedometer housing. I ask this because the last time I mounted my tire, we must have gotten it misaligned and ended up bending the tangs that turn the gear that turns the speedometer cable. Ended up having to take the gear housing apart and hammer the tangs back to flat. Speedo works great again. My Rotor rubs my brake pads pretty hard too.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #6 of 11 Old 04-08-2008, 10:11 PM
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+1 on the speedometer slots. Been there done that too on a previous bike- DX

94 KLR,tank guards,sw motech centerstand,Doo done, african switch,mirror dampners, powerpegz, twisted throttle fuses, aluminum skidplate, Bigcee shark disc and jug holder and subframe upgrade, progrip grips,maier handguards/brushguards, avon distanzias,fmf q4 exhaust, headlight guard, handlebar risers, billet rear brake reservoir bracket and guard, dual star shifter,garmin 2820 gps, tmod,disc cover, pcv mod,corbin flat
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post #7 of 11 Old 04-08-2008, 11:00 PM
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I had a similar issue my first experience with the front wheel. I quickly discovered that the two seconds it takes to remove the two bolts and take off the brake housing makes getting the wheel back on a breeze because you don't have to try and line up the rotor. Once the wheel is back on, then the brake housing just slides right on with no problems. Having it off also helps to make sure the pads are in the housing right.
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post #8 of 11 Old 04-09-2008, 06:07 PM Thread Starter
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Boy, I'm sure glad you guys mentioned that spacer. Seems it was stuck to the wheel when I took it off so I didn't notice it and off it went to the bike shop with the wheel. Problem is, it didn't make it back home with the wheel, when you guys mentioned it I went out and looked around the garage and then my car and then I got to worry over it all night.

I got up today and the only thing I had come up with was to go back to the bike shop and hope they had found it. Lucky for me they found it and all is well now.

The brake issue was solved by taking the caliper off and making sure I had it configured right.

Thanks for the help guys, this is another time you've saved LarryBoy from having to come over and rescue me.
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post #9 of 11 Old 04-09-2008, 06:14 PM
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I am glad you found it, and got it fixed. Those pesky spacers can be troublesome sometime. Oh by the way, the rear wheel has one or two also, don't lose em if you take it off...LOL

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #10 of 11 Old 04-10-2008, 09:50 AM
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Quote:
Originally Posted by Aztec View Post
Thanks for the help guys, this is another time you've saved LarryBoy from having to come over and rescue me.

All that worry is gonna make your hair fall out.




Quote:
Originally Posted by Swish~Married View Post
Larryboy, you're brilliant!!


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