[trmrz4422]

Try installing the front axle without the tire and see if it spins freely in both forks. Your forks may need to be aligned in the triple tree. Loosen one fork until the axle spins freely. Make sure it's greased. Then try to reinstall the rim/tire.

Will try getting around to this tomorrow and reply with results.

 

[trmrz4422]

So I got around to doing what you recommended sort of. I did this with the axle only and it wouldn’t get through the furthermore fork, it wasn’t until I tried putting it on with the wheel I realized the front stand was hitting the edge of the axle preventing it from going through all the way, so I spun the axle with the rim on it, no brakes, wheel spins freely forever in forks. Tried loosening the triple tree (bottom and top) before I put the wheel back on and tightened them up before adding the wheel. Got the wheel in with the same amount of force and fighting with the forks as usual. (I’ve found that I can use a flathead to pry the forks away from the rim enough to get past the spacers.) Once the spacers are inside the forks the axle lines up with the forks and yada yada, I felt like I didn’t accomplish much, I did take pictures along the way and those are posted here. The brake calipers do not sit evenly on the rotors. Left side, under the throttle, the outside brake pad was pushed all the way in, not able to see the pistons with its other pads extended out much further. The right side of the bike under the clutch lever, the brake pads weren’t as uneven, but still uneven enough to be not correct.

As you can see in the first picture, this was the "not as bad" brake caliper, you can see all 4 pistons. (didnt get a picture of the worse brake caliper, but the pistons closest to the mounting bolts; outside of bike, were not visible as the pads were flush with the caliper, causes rotor to slightly rub the caliper)

2nd picture shows how tight the forks hug the wheel WITHOUT the spacers (WITH spacers life is all hell.)

3rd & 4th picture show the rim without and with spacer.

Bike is now reassembled as it is my daily as of right now, ,let me know what else you need pictures of. please and thank you!

 

[trmrz4422]

Jeez, everything looks ok, shouldn't be a struggle to mount wheel.....
What's part # of wheel?

I am not 100% that this is the part number but this is what is stamped on the Spoke of the rim,
J 17M/CXMT3.50 DOT

 

[trmrz4422]

Maybe the wheel bearings were swapped out ( wrong size bearings ? ) or with the wrong spacer between them / the bearings not seated fully. Is the center spacer tight up against the bearings?
Can you get a good measurement through the wheel axle hole with the spacers in place ( as ready to fit ) and hopefully someone can compare or check what it should be. I have a '06 so can't help there, but maybe there is a spec for it written down somewhere? .
A measurement between the inside of discs would also help to confirm the correct wheel.

I have an exact replica of the rim sitting outside with the bike. I have tried swapping the rim the bike has on it, with that new rim that I know came off a 2008 600rr spec, however I had the same issue. I will try pulling old bearings out of the spare rim and replacing them with new bearings, and will measure the inside as well tomorrow. I have a bearing puller kit from Amazon (Bicos bearing install and puller) however i have no idea how to use it so I’ll have to figure that out tomorrow.

 

[trmrz4422]

If anyone here has the same generation bike / knows the specifications, I’m wondering what the distance between the two forks is at the bottom; the distance between the axle holes. That would be extremely helpful in telling me if the forks are the issue or not.

 

[trmrz4422]

Maybe the wheel bearings were swapped out ( wrong size bearings ? ) or with the wrong spacer between them / the bearings not seated fully. Is the center spacer tight up against the bearings?
Can you get a good measurement through the wheel axle hole with the spacers in place ( as ready to fit ) and hopefully someone can compare or check what it should be. I have a '06 so can't help there, but maybe there is a spec for it written down somewhere? .
A measurement between the center of discs would also help to confirm the correct wheel.

Sorry to take so long to get back to you, just measured the front rim that is currently NOT on the bike; figured it's easier than removing the current one. Measurements are as follows

Bearing to middle spacer to bearing is 5.25 inches.

From the end of the bearing to the end of the rim, there is about another 0.25 of an inch.

Measurement from Disc to Disc ON The bike was 5.50 inches. This was measured from the outside of the discs, granted theyre very thin.

As for the bearings, maybe i'm just a tard or maybe those bearings decided they weren't leaving their home. However, I was unable to tap those bearings out of the rim after going around the bearing tapping with a drift and hammer for about 30 minutes, made zero progress.

EDIT : I also noticed that the brake rotors are sitting on the outside of both calipers, as in they are not centered, the right side rotor (under brake lever) is on the right side of the caliper, pushing the right side pads ALL the way in

Vice Versa for the left side, left side pads are ALL the way in, rotor isn't centered.

 

[trmrz4422]

He said he couldn't get the axle to go through the other fork so the forks are not aligned. That needs to be step 1. And you can't do it using a fork tube stand. He still may have mismatched parts but starting at step 1 and moving through the process may help figure it out. Let's see what the forks look like at the top of the TT.

Post a pic of both forks.

 

[trmrz4422]

You can't align your forks with a fork tube stand. The weight of the bike is always on the fork tubes. You need a triple tree stand or a floor jack on the exhaust headers, not the oil pan. Once you get the weight off the forks then you can loosen one fork and align the axle correctly. Where are your forks in the top clamp? Post a picture. Then double check you have the correct spacers as Ronayers.com shows them as being the same on both sides. The calipers need to be cleaned as the pistons are dirty/pitted and may need to be rebuilt if they still don't align with the rotors.

Taking a second read at this message. I was considering getting around to this tomorrow, however, i believe the axle is correctly aligned, forks at the same height. The problem seems to be the distance of the forks, they just seem too close, which is why i have to jam pry the forks out a tiny bit to get the wheel and spacers in properly. I do have the correct spacers as they are both the same size. Calipers SHOULD be cleaned, yes. However it is not the cause or a even a factor to the issue as the rotors quite literally are close to grinding the inner wall of the caliper.

 

[trmrz4422]

You have a different thread stating you had a 1000rr wheel installed and had to replace it. That's very uncommon so it begs the question if there's other modifications on the bike, and, now that you bought a new wheel there's additional questions.



A few things:

1) Front CBR600RR wheels are interchangeable, BUT, the 03-06 and 07+ need the appropriate spacer set (see below.)



2) Sellers get it wrong all the time. Honda has made different CBRs and 600s and sometimes they're conflated by sellers.



3) Different CBR years and CCs as well as other Japanese bikes have used Tokiko calipers + 41mm forks. Can you take pics of the adjusters in the fork cap and fork leg to help rule out which forks are installed?



Note the combo of internal and external spacers for each year range. I wouldn't be surprised if the axle length is also different between 03-06 600rr and 07+ 600rr, and the possibility you have a 1000rr axle.

03-06 Wheel
View attachment 233627

07+ Wheel
View attachment 233628

Attempting to rule this out, the axle wouldn't be a factor if the problem persists before the axle is in the equation. AKA If im trying to mount the wheel between the forks and the forks are too close, the axle isn't even in yet ruling it not the issue right?

Spacers I have already ruled out as I do have two of the same spacers

 

[trmrz4422]

he might be saying you possibly have different forks on the bike, and not correct for the wheel you are trying to put on?

This could be possible. I'm not sure how to determine if the forks on the bike are correct though

 

[trmrz4422]

Correct, but we're trying to rule out as much as possible so without knowing what's on the bike the axle won't factor with initial mock up but may need replaced after we verify everything.

Pictures are going to go a long way to get us on the right track so can you provide the pic previously requested?

My thought process is if someone went through the trouble to replace the front wheel then I want to see what else is currently installed. That means the forks, the lower triple, and the upper triple. Also, just saying the forks aren't bent doesn't make it true because we're talking about millimeters of deflection which may not kink the fork stanchions or outer tubes but may still bow them.

What exactly on the triples and forks would you like pictures of, upper triple and top down view of fork images were posted above

here is what I have as of now

 

[trmrz4422]

We need pictures like he said
Top of fork where the adjustments are
Bottom of fork where the adjustments are if theres any.
And the height of fork cap from tripletree on both sides.

What side is the axle bolt on?

I replied to a post above with all of your askings. The axle bolt is on the right side of the bike, under the brake lever.

 

[trmrz4422]

picture of the bottom of the fork where the caliper would mount.

 

[trmrz4422]

Sure looks like a 07 600rr fork. Looks similar to 08 1000rr but the 600 is 41mm and 1000 is 43mm if memory serves.

So to be clear; the shop used a head stand or did they use a fork stand also? If there's not enough space to slip the wheel in and out with a head stand then you may have bent outer tubes.

Shop used head stand. My bike is 2008 600rr, meaning 2007 forks should be the same part. I found a 2009 cbr600rr front rim on marketplace, from the measurements the seller gave me, everything should line up onto my bike. If anyone knows that the 600rr from 2009 is incompatible please let me know before this weekend.

However, if the fork outer tubes are bent i might be adding more money into the drain for nothing.

Is there a way to be sure of outer tubes being the issue, realistically it would be such a fractional difference that it would be impossible to eyeball i'd assume.

 

[trmrz4422]

before going to buy a rim and pulling out forks, would you want to try maybe removing the rotors from the wheel and just see how the wheel fits again? i know it seems kinda redundant, but you can triple check i guess and maybe just check the part numbers on those rotors as well... we are clearly doing a teardown investigation on this poor bike :/

I got the wheel off, took the rotors off, tried to remount the wheel. With spacers it’s practically impossible to mount it as the spacers will he blocked by the bottom of the fork. Next course of action? Removing the forks, what would that tell me, and what should I do / check with them

 

[trmrz4422]

I don't know if this has any significance but my axle sits flush with the fork on this side. Also brake discs are not oem - those bobbins don't look oem.

I think you're onto something here and I think it comes back to the forks being bent / closer together on the bottom causing my wheel to not fit correctly.

 

[trmrz4422]

PROGRESS UPDATE!

I managed to get the wheel on with no problem this time. How I did it? I listened to

You can't align your forks with a fork tube stand. The weight of the bike is always on the fork tubes. You need a triple tree stand or a floor jack on the exhaust headers, not the oil pan. Once you get the weight off the forks then you can loosen one fork and align the axle correctly.

So I set the bike on its headers and loosened the right side bolts on the bottom triple clamp, wheel slid in like BUTTER! Axle aligned, bolts placed, everything torqued to spec. Problem still exists with the rotors. I mean realistically it has to be the crappy aftermarket rotors the shop ordered after stating my OEM ones were bad, yes ONE of my OEM ones is bad.

Considering ordering just ONE oem one, and using the good oem one that I still have. From what I know the rotors on the 08 600rr are interchangeable? There are no left and right rotors correct?

EDIT : Measured the spacing on my aftermarket rotors, they are spaced roughly 5.50 inches apart, if anyone could let me know the offset they are supposed to be at / what OEM rotors are offset by that would be perfect

 

[trmrz4422]

If you look right above your post, someone took pictures with the tape measure. I believe he has 13 cm from rotor to rotor which is about 5.2 inches I believe.

Replaced with OEM brake rotors. Issue still persists. If the inner tube of the fork isn't smooth, would they leak at all or no? My forks have no leak at all on either even after being beaten on, couldn't notice any gauges even using a flashlight behind the fork and rolling it. Would rather not replace the fork components if im not 100% sure thats the problem as they are quite expensive from what i've seen.

EDIT: Im wondering if its possible that I have the wrong axle, and the axle doesnt pull the front together causing the forks to be further out than they should, making the rotors grind?

As said prior, and seen. My axle does not sit completely flush with the outside of the fork.

 

[trmrz4422]

What is your measurement from inside of fork to fork like the guys photo above?

With the wheel mounted on the bike inside of fork to fork is 6.5inches.