Does this make sense??

[Maddog]

Can anyone with a better IQ than mine read the following and see if it makes sense??

Its regarding zx10 04/05 front wheels on a zx10 06/07...

the 05 bike uses a 20mm axle and the 06 has a 25mm axle so all you need to do is use the 05 axle and have a sleeve made to go through one side of the fork leg.

Right then, before we start...

Left and right as you sit on bike, OD = outer diameter, ID inner diameter

All rears 04 -09 interchangeable (colours vary), all using 20mm spindle. 06 has different caliper carrier though.

04/05 front: 20mm spindle. 04/05 forks - left side 25mm hole with captive nut, right side 20mm hole for spindle to go through.

06/07 front: 25mm spindle. 06/07 forks - both sides 25mm holes - uses 25mm axle all the way through with a nut on the outside left.

Both spindles go in right to left. The key to making this work is the fact that both fork left side holes are 25mm.

So using this information, to put an 04/05 wheel into 06/07 forks we need an 04/05 spindle because a 25mm 06 spindle will not go into a 20mm 04 wheel axle hole.

The left side 04 captive nut goes straight in 06 left fork bottom (both 25mm), so the only problem is the right side as we have a 20mm 04 spindle in a 25mm 06 fork hole.

Go to a local machine shop and have a shim/bush made up as attached picture, this will take up the slack around the axle on the right side. The split is important (can be cut with a hacksaw after turning) and you should align it with the bottom of the forks as this will allow the pinch bolts to grip/clamp the shim onto the axle. Specs - OD 25mm, ID 20mm, Length - 39mm.

SO TO PUT AN 04/05 WHEEL INTO 06/07 FORKS YOU WILL NEED AN 04/05 SPINDLE PLUS THE SHIM.

[ash]

As another alternative, if you knocked out the bearings in the 04-05 front wheel (providing the bearings have the same O/D as the later model), that you couldn't go to a local bearing or seal suppliers with the etched bearing codes you already have from the existing later wheels, and get a set which take the 25mm spindle ?

It would be a bit less of a hassle and you'd get new bearings in the front wheel to boot.

Worth an investigation ?

[Maddog]

I did read something about replacing the bearings.......i cant remember exactly what was said but it was a no go. I think the bearings stuck out too much....or something similar

[ash]

If you speak to the bearing supplier, you may well find that they can offer an alternative which is rated to the same spindle speed, and fit the hole and spindle.

We use a local firm called http://maydayseals.co.uk/

but there are a few more we use as a company for our lathes and mills. I've bought head race and wheel bearings for my G1 and B1  from them in the past for a fraction of the cost of the Kawasaki parts (Kawasaki like all bike manufacturers don't make bearings, but select from a catalogue for the standard ones to fit their specific requirement) Mayday are very knowledgable, but there are another 3 or 4 in the Gloucestershire area which sell bearings as well. You should find someone local to you.

Bearing codes are usually etched on the face of the outer shell, you should be able to read them in situ

Tell them you need a bearing which has a 25mm hole through it instead, and give the existing bearing code to match the outside diameter and thickness.

[Maddog]

I think the issue with that is the 04/05 rim takes a 20mm spindle. The 07/08 takes 25mm. On the 04/05 One fork leg has a 25mm hole and the other has a 20mm hole. The 07/08 has 25mm both sides

[ash]

My suggestion is getting (if you can) some larger internal diameter wheel bearings to fit in the 04-05 wheel which can take the 25mm diameter spindle. I would be very surprised if nobody was making them.
That would avoid the need to get anything fabricated, and give you a quick and relatively straightforward fix off the shelf.

[Maddog]

Sorry mate if im being a bit dim 

The 04 wheel hub is only big enough to take the 20mm spindle. Theres no way of getting the 07 25mm spindle through the hub

[Maddog]

Right......after hours of digging ive found a couple of answers.......the first is to make the shim as previously mentioned....

dimensions are..OD 25mm, ID 20mm, Length 39mm. Split along length

Heres what it looks like fitted....Close up is of 20mm 04/05 spindle with the shim in right side of 06/07 fork bottom  - this is what allows 04/05 wheel to go straight in...



The second option is " use 42-25-12 bearings , these are available from most bearing shops and this there is no need to get collars made up. these bearings fit straight into an 04 wheel and its an easy way to fit them straight in"

I cant seem to find the bearings of that size nor can the bearing suppliers ive contacted soooooooooooo i think it leaves me with only 1 option! How safe does the "shim" method sound?

[Jonesy]

try Orbic bearings in Croydon, they are pretty good!

http://www.orbic.co.uk/

[ash]

If no joy there, try

http://maydayseals.co.uk/ Cheltenham

http://www.brammer.co.uk/bearings_seals.htm Tewkesbury

http://www.hayley-group.co.uk/branch-finder/branch/bearings-motors-gloucester/  this one may have a local depot to you.

Aerospace and engineering is very active around my way. there are others to try but I've used Mayday and Hayley and they are sound (mayday know their onions for sure)

[Maddog]

Im awaiting a reply from Orbic. Mayday can only do the ones listed in my previous reply. I will email the other 2 firms! Fingers crossed!

[Carbon_ZX6R]

enough digging about and your get there in the end mate

[Maddog]

Cheers dude. I will start another thread re the bearing and hopefully someone will guide me to the right place....then i can.. 

[ash]

There is a company in Tewkesbury called phoenix bearings.  They are manufacturers not just stockists.  I looked at a job there when I started in engineering 25 - 30 years ago

They are may be able to help

[Maddog]

Cheers Ash, i will mail them.