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My service manual doesn't go in to detail about the ridge and the drill bit or any of that stuff. I am confident now that I need a slightly longer bearing spacer as my right slider tries to bend inwards to take up slack as I tighten the axle nut with a drill bit in the hole. I'll go to the dealer and order the next two longer sizes and see which one works out for me.
Put the axle together with the brake caliper in place without the spacers. You don't have to torque it down, but snug it up and place the fork with the drill bit properly. Then make sure the tire is centered. Using the fender as a starting point to make sure the tire is centered. The brake pads will re-align once you get it together properly once you have the proper spacers and all torqued back together..
Then measure with a caliper the size of spacer required on each side. they sell the spacers in thousands of an inch. That is: a 3/4" spacer is 0.750 give or take. My 3/4" spacers are 0.732
If you are hell bent on the tapered spacers, you have to make sure the lips on the one side of the spacer contacts the inner bearing race and not the hub.
Yeah my spacers turn freely agains the bearing inner race, no hub contact at all. I'm about to go pull it apart and take some pictures if it doesn't line up
So I got the right spacer and all is well in the world. The spacer length I needed was 3 7/8" I had a 3 3/4". 1/8" too short, and what a world of difference that made. I didn't even have to align the right slider with a drill bit. After the axle nut was torqued to spec, the hole in the axle is perfectly aligned on the edge of the right slider. Torqued down the slider cap and its all great now. That nice tapered spacer now has that 1/8" gap away from the hub but honestly how many people will be looking at my front wheel anyhow. Thank you again to everyone for all the advice!
Yep, it was just a matter of taking it all apart again and measuring. I did the mock up without the wheel to make sure it was going to work and its all good in there. Found a broken wire for my headlight as well, so that was an easy fix. Should be riding tomorrow after my HID kit install.
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