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I'm surprised to hear you have trouble with assembling with rotor mounted on the wheel?
I'm using a 6" wide wheel with the 200mm tire and I remove the caliper first, remove the axle, jack up a few inches and roll out the wheel complete with pulley and rotor attached.
It might only be because I did this trying to hold up the wheel and get the caliper in there at the same time but it might also because of the 16" wheel and the wave rotor I use. I might be able to when the tire is on the wheel and I don't have to hold the wheel up while I align everything.
I have a 16x5.5 amd can't get the caliper off or on without removing the rotor. Mounting the entire assembly (spacers, caliper, bracket, wheel) in one go is a bit of a 3-handed job. I made a wood dowel that's just a fraction shorter than the inside width of the swinger and slighlty smaller OD than the axle so that I can hold everything in place while I slide the wheel assembly in. One there, I push out the dowel with the axle and Carry on with alignment, etc.
Last edited by cggorman; Aug 17, 2019 at 08:13 AM.
I have a 16x5.5 amd can't get the caliper off or on without removing the rotor. Mounting the entire assembly (spacers, caliper, bracket, wheel) in one go is a bit of a 3-handed job. I made a wood dowel that's just a fraction shorter than the inside width of the swinger and slighlty smaller OD than the axle so that I can hold everything in place while I slide the wheel assembly in. One there, I push out the dowel with the axle and Carry on with alignment, etc.
Great tip cggorman you have mentioned before.
Just like I have to assemble mag catches with magwells.
I made a wood dowel that's just a fraction shorter than the inside width of the swinger and slighlty smaller OD than the axle so that I can hold everything in place while I slide the wheel assembly in. One there, I push out the dowel with the axle and Carry on with alignment, etc.
This is a great idea, Chris! Whether front wheel or back, I always lift the bike on the J&S lift, then I use my old Sears jack to raise and lower the wheel. It keeps both hands free, and it's easy to make small adjustments with the jack.
Necessity is the mother of invention? Nah. More like biblical frustration is the mother!
Don't know how many times I dropped a spacer with the assembly 3/4 of the way home. Usually one that was partially recessed into a counterbore so I couldn't just slide it back in without starting over. Chipped a lot of fresh powder coat and polished metal and used a lot of rather impolite language before I asked myself why I was doing it the hard way.
Well, I got the new rotor bolts, tire, and wheel in and then the tire mounted on the wheel yesterday but it seems UPS has lost the shipment of my pulley bolts so who knows how long till I get this put back together.
So got the rest of the parts in and went to put it together last night. Got the pulley on first.
Went to assemble and it was a PITA. So with the 16" x 5.5" I had to try several different procedures to get everything in place before inserting the axle because the caliper doesn't slide between the rotor and the wheel hub when the rotor is already installed. What I ended up with for procedure was to roll the wheel in, put the belt on the pulley, get the caliper positioned and held up with a string to the sissy bar, get the left side spacer positioned, slide the rotor in between the caliper and the wheel then slide it in to the caliper, slide the caliper and rotor as far back as they could go and roll the wheel forward a bit so that I could get the right side spacer in between the caliper and the hub, slide the caliper and rotor back in place, then bolt the rotor to the hub. That was just to get it in place. It was tight and no fun to get the axle to slide in but now that I know the order it should be simpler. I checked alignment, runout, and spun the wheel a bunch to see where the belt was going to run on the front pulley. It is closer to the outer face but still about 1/8" from it so that is good news. Bad news is I noticed some belt damage when I was spinning the wheel. Not enough to necessitate an immediate change, but I won't be gunning it or traveling too far on it before I can get it changed out this winter. Overall I like the new look, the handling due to the wider tire and slightly lower back end will take some getting used to, and I look forward to getting the front wheel replaced so that it matches once I wear out the front tire.
Last edited by Jay Guild; Aug 23, 2019 at 09:05 AM.
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