Front end damage from crash - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 9 (permalink) Old 9-8-2019, 4:24 PM Thread Starter
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Need Help After Crash

I crashed my 09 ex500 on Sunday and I was hoping I could get help identifying what I need to do to get her back on the road. I attached a picture and a video of the front axle is here:

I followed a couple threads on fork alignment but i couldn't get it completely straight. I'm not sure if the clamps are bent or not but the forks do bind up when twisting them so they probably need to be replaced.

Also when I was unscrewing the front axle, it was spinning as if it was bent too. Would I have to replace just the axle or could the wheel itself be damaged too?
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Last edited by GeneralBones; 9-8-2019 at 8:16 PM.
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post #2 of 9 (permalink) Old 9-8-2019, 9:27 PM
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very difficult to analyze each component via keyboard. I see a NYS inspection sticker...where are you? Upstate? Downstate? General location, town, borough, county?

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post #3 of 9 (permalink) Old 9-10-2019, 1:27 PM
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I have encountered front end damaged EX's several times now and have become familiar with what gets bent and where.
First off, your forks are likely bent. It'll be minor, but they'll bent right below the lower triple. The triples, both upper and lower, usually get bent as well, though it's hard to notice. What will happen is the forks will be replaced but the owner will still wonder why they were hard to install and why the front wheel is still crooked. How this happens is that as the forks are bent and tweaked over, they force the triples to bend with them. Your accident was minor enough you may have gotten away with just a bent lower, but you should still remove it and check for straightness, which is easy to do. For the lower, remove it and set it on a good, flat table and hold one of the clamps flat. If the other clamp does not sit equally flush, it is bent. The upper is a little more annoying as you can't set the whole thing flat against a table, so you'll have to get creative. I'd suggest grabbing a quality sheet of plywood or any other decent cut of wood. notching it to fit the center ignition mount and using that to see how flat it is.

Judging by your video, I'd also say your axle is bent.
Your wheel may be bent as well. That's not hard to determine. Get some tall jack stands, run your new, straight axle through the wheel, rest it on the stands and give it a spin. A bend or flat spot will make itself apparent.

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post #4 of 9 (permalink) Old 9-11-2019, 10:07 PM Thread Starter
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Thanks for the replies. I'm in the Troy Albany area. I was able to what looked and felt like completely straighten out the alignment but the when I do the test where you use a piece of glass against the forks under the lower clamp, it teeters like a chair with an off leg. So yeah forks will be replaced and I'll take off the clamps to see if they got bent too. I'm really hoping they aren't. Thanks for letting me know how to go about the clamps and wheel 🙂
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post #5 of 9 (permalink) Old 9-14-2019, 11:41 AM Thread Starter
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Update: I haven't taken the axle out or anything to check for bends but I was able to completely align the wheel and test it in a parking lot. It seemed completely fine up to 45mph but I can't really do much testing since my leg is still a bit crippled lol. I'm gonna take it apart sometime this week. I'm curious, what could happen if I didn't replace the forks or anything? It sounds really unsafe
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post #6 of 9 (permalink) Old 9-14-2019, 1:28 PM
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copied and pasted for your perusal:
OK the forks are Tweaked.

With the bike on the center stand and the front wheel propped off the ground. Loosen all
the Triple clam pinch bolts, the top center cap nut. and the Axel and the Axel pinch bolts. Don't remove any of them just get them loose.

Check if your fork tube are bent by twisting them in the triples. they should turn freely. if they move a little then bind they might be bent.

Now rock the tubes as above, Hold the front wheel with your knees and twist the bars till the plate Don't rock.

Now gradually tighten all the bolts a little at a time as you keep checking the "Rocker" till all are properly torqued.

Your done, your front end will love you for it.

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post #7 of 9 (permalink) Old 9-14-2019, 6:06 PM Thread Starter
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I remember reading that. Is this process for straightening the forks back to normal? Or is it for just aligning it? I figured it was just to align the wheel and handlebar.
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post #8 of 9 (permalink) Old 9-14-2019, 7:00 PM
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Quote:
Originally Posted by GeneralBones View Post
I remember reading that. Is this process for straightening the forks back to normal? Or is it for just aligning it? I figured it was just to align the wheel and handlebar.
It will tell you if they are straight, and align them if they are

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post #9 of 9 (permalink) Old 9-15-2019, 2:08 PM Thread Starter
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Alrighty thanks. I'll be able to properly do that in a few weeks once my legs done healing
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