GS500 - Front wheel/rotor/caliper clearance.

[PJFZ1]

  I'm new to the GS500 (but not motorcycles or wrenching).  I bought a '99 GS500, and the front tire was trash, so I've had it parked till I for the tires here, and went our to do the change today.

I removed the front wheel, changed the tire, the re-mounted the front wheel.. Didn't screw with the bearings, etc, just changed the tide on the rim.

The small threaded boss on the caliper that bolts to the lower fork leg just barely taps the buttons on the brake rotor as the wheel rotates, and I can't find any indication that I'm missing any spacers or washers (checked the microfiche and spoke to another owner).  Thos buttons on the rotor also pass very close to the lowe fork leg.

  How much are the clearances here normally? With the front end off of the ground it's very noticeable, but when the weight is back on the wheel it's very minor, but still not right.

Anyone else had this experience?  What's the cause/fix?

[coll0412]

Hmmm thats a toughy.

I have heard of this problem before. Try a search and see if you can come up with some info.

[werase643]

are the caliper bolts 12 or 14mm bolt head or 6-8mm allen head

i'll guess bolt head...and they are too long....

[PJFZ1]

are the caliper bolts 12 or 14mm bolt head or 6-8mm allen head

i'll guess bolt head...and they are too long....

The head is on the outboard side of the fork, and don't protrude through the caliper threaded hole.

[werase643]

are the brake pads real thin....?

[PJFZ1]

I'd say 50%, I'll get new ones on order tonight, but even if that clears it up, I cen't believe they should be that close..

[werase643]

1 are your fork tubes bent?
2 is the spacer on the fork tube loose...the one clamped in the lower leg?

if it is not loose..... it might be pulling your right fork leg towards the center when you tighten the axle.....

[PJFZ1]

Haven't disassembled a tube to check.. but it touches with the axle loose... How close is the stock clearance?

[werase643]

to check tubes....loosen tube in the tripple and rotate tube and see if the end of the lower leg move fwd/back...left / right

the spacer in the lower leg needs to be loose
when re assembling the front end...after a tir change....
install axleand tighten  and loose fit brake...
then bounce the suspension to settle everything
then tighten the lower leg...spacer clamp

if everything is straight.....that should fix it.

[PJFZ1]

Agreed with your procedure, but it's not allowing any more room..  The front end is loose and free and I'v got the minimal contact.
  How close is that stock clerance? Is it normally just a mm or 2?

[werase643]

yes, real close
but nothing should touch....ever

[PJFZ1]

I agree on the touching... But I'm busy filling orders tonight... Might be able to look again tomorrow night.