While riding I was noticing a click sound from up front. What I found was about 1/2 inch of free space between the bottom of the frame neck and the lower triple tree. When I would take off the front end would lift and hang there because of the angle, then if I hit a bump the front neck would drop back down causing the click. Should I fill this space with washers or a spacer? Seem like the front neck is taking a pounding due to the large gap???
Doodlebug front fork/neck gap
- Thread starter IPDDave
- Start date
Mine has the gap too. Fortunately they left the assembly instructions in the packet I got with the bike and according to the instructions there's supposed to be tapered washers on both the top and bottom of the steering bearings that take up that gap. Unfortunately they charged me a $30.00 prep fee to put it together incorrectly. I've been in contact with Baja Motorsports to try to get these washers with not much luck yet. The weird thing is that they're not listed in the parts manual so it's been so it's been a pain in the @$$ trying to get them. If I find something out I'll post it.
The flat washers are on the outside of the fork mounts and the tapered ones go between the frame and fork mounts. There are four washers in all. They're probably not noticeable when assembled correctly, you just don't have the gap. Pep Boys says the washers weren't with the bike but the one they have on the floor has them on it in the wrong position (based on the Baja Motorsports official assembly manual, not my opinion). They don't seem to want to help me at all.
OK guys I have found the "tapered" washers that are suppose to be in the neck. The washer people call these Conical Washers. They are important to have in, because then the upper and lower tree are bound to the neck bearing. Thus tightening the front fork bolt will NOT bind the front end. Also, the tension rides on the bearing - where it should. The upper and lower tree will have a slight bow from tightening to the required 20 ft. lbs., but that is perfectly OK. It is an engineering design to add extra tension to the fork bolt and nut. MOTRA was having problems locating them - the factory doesn't know that they exist. You can purchase them from Fastenal. Just do a web search for Fastenal. Its part or sku # 40276 - M10 Plain Finish Conical Washer for .36 cents each. Then the frontend will be safe and proper..........IPD Dave
Anyone have any pics of these spacers?
I just disassembled the front-end of my DB-30 for a general inspection. Aside from having the feeling that it was not assembled correctly. I found that the top bearing was not turning freely.
The original bearings are not weather resistant or moisture proof. The bearing number is: #6900 Z
I replaced the original bearings (#6900Z) with a set of sealed bearings with the part number of: #6900 RS
Thanks
Supposedly the "RS" designates "Rubber Seal"
I just disassembled the front-end of my DB-30 for a general inspection. Aside from having the feeling that it was not assembled correctly. I found that the top bearing was not turning freely.
The original bearings are not weather resistant or moisture proof. The bearing number is: #6900 Z
I replaced the original bearings (#6900Z) with a set of sealed bearings with the part number of: #6900 RS
Thanks
Supposedly the "RS" designates "Rubber Seal"
After seeing this thread, I looked at our 3 DB's, and found a lot of difference.
Original DB (yellow) purchased used: appears to the washers in as I can see a washer and there is no gap.
DB (red) purchased new at Pep Boys spring 2009: has a gap just as noted in this thread.
DB (red) purchased this 3rd one at PB in spring 2009: does not have a gap, but cannot tell if there is a washer in, because looks like bolt was tightened down hard enough to bend top horizontal piece on fork.
Later this week, I think I will disassemble the 2 red DB's and check over. Thanks to others for posting part numbers and solutions to this issue.
Original DB (yellow) purchased used: appears to the washers in as I can see a washer and there is no gap.
DB (red) purchased new at Pep Boys spring 2009: has a gap just as noted in this thread.
DB (red) purchased this 3rd one at PB in spring 2009: does not have a gap, but cannot tell if there is a washer in, because looks like bolt was tightened down hard enough to bend top horizontal piece on fork.
Later this week, I think I will disassemble the 2 red DB's and check over. Thanks to others for posting part numbers and solutions to this issue.
Yesterday I took the front forks off my one DB30, and found a few things which were not correct.
- Conical washers are missing. Looked on-line at Fastenal's web site, and part number which IPDDave gave is correct and listed, only problem I had is that it noted that all area Fastenal stores did not have this item in-stock, but they said it was available on-line. My local Fastenal store is not open on Saturday so I will check on Monday to see if they can order these items. I did try to order on-line, but could not figure out how to register, or seemed that if was only for wholesale business? Hopefully the local stores can order.
- Pep Boys assembled the front forks incorrectly - had the wheel hub spacers on backward (the short piece is suppose to be on the left side). Not sure if this makes any difference, but reinstalled it correctly.
- Also found that there was not a large washer on the front wheel assembly in front of the caster nut. Went to the local hardware and purchased a washer for .15.
Really makes me wonder if they even looked at the installation instructions when they first assembled at Pep Boys?
- Conical washers are missing. Looked on-line at Fastenal's web site, and part number which IPDDave gave is correct and listed, only problem I had is that it noted that all area Fastenal stores did not have this item in-stock, but they said it was available on-line. My local Fastenal store is not open on Saturday so I will check on Monday to see if they can order these items. I did try to order on-line, but could not figure out how to register, or seemed that if was only for wholesale business? Hopefully the local stores can order.
- Pep Boys assembled the front forks incorrectly - had the wheel hub spacers on backward (the short piece is suppose to be on the left side). Not sure if this makes any difference, but reinstalled it correctly.
- Also found that there was not a large washer on the front wheel assembly in front of the caster nut. Went to the local hardware and purchased a washer for .15.
Really makes me wonder if they even looked at the installation instructions when they first assembled at Pep Boys?
I recently checked out the front end of my DB-30. This one wasn't to bad compared to some of the stories here. The other day I picked up another DB-30 & it has a lot of slop in the front end. I have not torn into it yet to inspect it further.
The conical washers that were installed on the first DB-30 are very slight. I really had to examine the profile to determine what side was what. If you look closely enough you should be able to see that one side will engage the inner bearing race, but if you flip it over, it will not.
I recommend that everyone replace the original bearings with a sealed bearing. Here is the info from my previous post on the steering neck bearings.
The original bearings are not weather resistant or moisture proof. The bearing number is: #6900 Z
I replaced the original bearings (#6900Z) with a set of sealed bearings with the part number of: #6900 RS
Here's a few pics of the bearings. Check out the black bearing. That is the rubber seal to keep moisture out.
The conical washers that were installed on the first DB-30 are very slight. I really had to examine the profile to determine what side was what. If you look closely enough you should be able to see that one side will engage the inner bearing race, but if you flip it over, it will not.
I recommend that everyone replace the original bearings with a sealed bearing. Here is the info from my previous post on the steering neck bearings.
The original bearings are not weather resistant or moisture proof. The bearing number is: #6900 Z
I replaced the original bearings (#6900Z) with a set of sealed bearings with the part number of: #6900 RS
Here's a few pics of the bearings. Check out the black bearing. That is the rubber seal to keep moisture out.
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