03 Chopper Front End Issue

[roadie1389]

Greetings

03 Chopper - stock wheels... Just had to rebuild the front end and now I am having an issue getting everything to align right. Note - this is a second hand bike and I am just learning this things and me and it are going rounds with each other. I had the front tire replaced by somebody else so I have no idea the arrangement of things prior to this.

When I put the front end together everything was fine except the front wheel center line did not match the centerline of the fender. I kept the spacers in the same place (and did not think to look if they were different). Well a few rides later saw that the fender bolts had rubber a bit of the tire. Measured and it looks like the 2 spacers are different. I took it all apart and swapped the spacers. Now the center lines match but the fender is not sitting right and now the other side fender bolts are close to the tire. Tried moving, wiggling, pushing the fender around and still not sitting right.

So question -
1) Should both spacers be the same size? if not, which side should the shorter one be on?
2) Are these fender prone to not site right? All the mounting bolts are lining up.

Thanks

 

[Mr. Wright]

I also have the 03, and have had the front end apart many times, so lets see if I can explain this.
On the spacers, Lets forget about them for a minute, and alien the tire first.
You will notice when you put the axle up into the bottom of the lower fork tube, that there is a space on either end of the axle, and it can be slid side to side. It needs to be placed so the brake rotor is riding in the center of the brake caliper. The little washers, between the caliper and the bracket, where it bolts on, are for fine tuning center.
Once that is centered, install your fender, so the tire is running evenly between the bolts. On mine, I have a spacer on one side and not the other. I also when centering my axle, for the center of the brake caliper, put a washer on the end of the axle, so when I have the tire off, I know where center is when reinstalling.
The main thing is centering the rotor and brake caliper, the rest is cosmetic.

 

[woodbutcher]

something to check also, was the tire replaced with a MH90 or a 90/90 ? should be a MH90.

 

[FrankBDPS]

Yes, you must center the rotor in the caliper first. Also you may need to push you're pistons back into the caliper before you start. I don't know how but someone may have jammed the wrong spacers in there to start with. But take you're time and get the rotor correct first. Also check you're brake pads to make sure they are worn evenly. There was a guy on here just recently who had his front brake lock up and went down. So get it right.

Another other questions don't be afraid to ask.

Good luck

 

[roadie1389]

Yeah, I've done that, but the fender is still not lining up right. I will have to work on it later after my real job. Anybody have a good photo of how their front end looks?

 

[Mr. Wright]

Not exactly sure what your wanting, but here are the best angles I could get.

 

[roadie1389]

Thanks for the photo. It turns out the front tire is a 90/90 which is a bit larger than the MH90. I can get the rotor to run center no matter which way I put the axle spacers, but the way the tire sits in the fender is never right. It rubs one way or the other. It does appear your front end is not the same as mine.

 

[Chillin]

the wheel need to go to the RIGHT ...look at the caliper center (the seam)... it looks like you have enough space.

most are shit fit from the factory...the fenders seem like it was a hurry up project
for fit

 

[Mr. Wright]

Yea, and the 03's are fiberglass, so they're not straight to begin with.

 

[roadie1389]

I have no idea how this crap ever fit together. What I need to find are 2 equal length axle spacers and it would put the wheel where it needs to be and the caliper and fender would all line up.

Thanks for all the replies.

 

[Mr. Wright]

I have one spacer laying around here. It is 1.4630" long

 

[ground pounder]

It also looks like your tubes are not straight with each other. This will through the fender off big time! loosen the pinch bolts on the triple tree and align the tubes so they are straight!!!

 

[FrankBDPS]

I thought something did not look square.

 

[roadie1389]

Well hopefully I did not loose any credit around here. But did a few things:

• Found a 2004* parts list document and the spacers I have are the correct ones from the factory.
• Loosened the pinch bolts, fork brace, took fenders off,took axle apart.
• Put the front wheel on with the spacers swapped. Tightened axle.
• Adjusted fork brace and tighten bolts.
• Set fender.
• Tightened pinch bolts and set the brake caliper.

Now everything seems to be sitting better, Also the front tire was a 90/90 so a new MH90 is coming.

Also, I suffered a duh moment. For some reason I was told the bike was an 03 Chopper but it is actually a 04 Chopper DT. This explains why the front end does not match yours. Also explains why I did not understand what Curtis was saying when I was asking about parts for the bike when I replaced the front end. Anyway, I appreciate all the help.

 

[Th3InfamousI]

Well hopefully I did not loose any credit around here. But did a few things:

• Found a 2004* parts list document and the spacers I have are the correct ones from the factory.
• Loosened the pinch bolts, fork brace, took fenders off,took axle apart.
• Put the front wheel on with the spacers swapped. Tightened axle.
• Adjusted fork brace and tighten bolts.
• Set fender.
• Tightened pinch bolts and set the brake caliper.

Now everything seems to be sitting better, Also the front tire was a 90/90 so a new MH90 is coming.

Also, I suffered a duh moment. For some reason I was told the bike was an 03 Chopper but it is actually a 04 Chopper DT. This explains why the front end does not match yours. Also explains why I did not understand what Curtis was saying when I was asking about parts for the bike when I replaced the front end. Anyway, I appreciate all the help.

MH90 will fit just runs very snug. I only get a little rub when parellel parking and moving the handlebars more than when riding. I ordered the wrong one and didn't realize until after it was on.

 

[FrankBDPS]

Glad you got it fixed!

 

[Brew]

Good deal, sounds like you got it...

 

[awg]

Yea I thought your fender brace was from a 04. Not sure but it could make a difference.

 

[woodbutcher]

MH90 will fit just runs very snug. I only get a little rub when parellel parking and moving the handlebars more than when riding. I ordered the wrong one and didn't realize until after it was on.

did you mean to say MH90 or 90/90, because MH90 is narrower and the proper one.

 

[Th3InfamousI]

did you mean to say MH90 or 90/90, because MH90 is narrower and the proper one.

Yep sorry typo!