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Dtown's Mobile Tech.
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901 Posts
Discussion Starter #1
For those of you who have purchased a Flush Mount axle, here are a few pics and some instructions on how to put them in.

INSTALLATION INSTRUCTION FOR FLUSH MOUNT AXLES

1) RAISE BIKE FRONT END UNTIL TIRE IS ¼” OFF THE GROUND.

2) REMOVE THE FRONT AXLE.

3) APPLY ANTI-SEIZE TO THE NUT CAP, AND NEW AXLE SHAFT.

4) INSERT THE NEW THREADED FLUSH NUT CAP UP TO THE KNURL IN
THE LOWER LEG.

5) INSERT NEW AXLE, USING ½” DRIVE RATCHET AND 9/16 SOCKET.
TIGHTEN UNTIL NUT CAP IS FLUSH WITH LOWER LEG.

6) USING A TORQUE WRENCH AND A 9/16 SOCKET, TIGHTEN THE AXLE
TO 55 FOOT POUNDS.

7) PLACE THE FLUSH MOUNT HEX COVER END CAP IN THE PINCH CAP
SIDE, HOLDING IT FLUSH IN PLACE, TIGHTEN THE PINCH CAP.

NOTE: IF THE NUT CAP WILL NOT FIT INTO THE LEG (3) FOLLOW THESE
INSTRUCTIONS.
WHAT HAS HAPPENED IS THAT THE ORIGINAL AXLE WAS SO TIGHT THAT
IT MUSHROOMED THE OUTSIDE EDGE OF THE AXLE HOLE, MAKING IT TO
SMALL FOR THE NUT CAP TO ENTER. MEASURE THE O.D. OF THE NUT CAP
AND USING THE SAME SIZE REAMER, RUN THE REAMER THRU THE HOLE
TO CUT AWAY THE MUSHROOMED EDGE. DO NOT TRY TO USE A DRILL
BIT.

This is what you should have received.



Apply anti-seize to this part


Also to the axle shaft


This is what your finished product should look like.
 

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Dtown's Mobile Tech.
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901 Posts
Discussion Starter #4
If you are installing these on an ABS unit you are going to want to look into removing the sensor BEFORE you set the end cap into place. AS the force required to pull the cap into place will more then likely crack the sensor. I have not done an install on an ABS unit myself but I would look at just putting it off to the side and replacing it with a few 1" washers to take up the space difference then I would pull the end cap into place and then remove the axle to replace the sensor to where it belongs.

Also keep in mind that I highly recommend that you take the 5 mins it takes to pull the front axle out and re-apply the anti-seize the the length of the axle at every oil change, as it will be almost impossible to remove the axle if it ever gets stuck in there and rusts into place like some of the bike I have had to work on in the past, that have lack of maintenance done to them. :bash:
 

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Dtown's Mobile Tech.
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901 Posts
Discussion Starter #5
Another method would be to get a 3" long threaded all the way to the top, 1/2-20 UNF grade 8 bolt and a nut and washer, remove the wheel and fender, twist the fork leg sideways and pull in just the cap without using the axle at all. I am working on getting a few of these set-up made and will be sending them out for any-one who would like one with the axle's in the future.
 
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