Disc brake install- front wheel alignment

Alright XJ Wizards! I've got one I couldn't find on here.

I've got an 82 XJ750 Seca. I'm just finishing up front end of the bike. MC rebuilt, fork seals, SS lines, anti-dives rebuilt, calipers rebuilt, new bars, cables, switch cleanup, atari cleanup.... Just fought the front wheel in. Then had to fight the calipers into position (specifically, clearance between caliper mounts and disc on right side was not enough to slide caliper into position. Remedied with some wood and a dead-blow hammer.)

Now that I've got pads in, and front wheel mounted, I'm finding drag on the (rider's) right side of the discs from the caliper mounts. I'm afraid to put the bike back down and start bleeding process.

Will the disc move over from the caliper mounts when I start adding fluid to the system? Or do I need to fabricate a shim for between wheel/disc and right fork?

Right side:



Left side, for comparison:

 

last time this happened to someone the front forks were twisted or speedo hub was not installed correctly

do you have all the required spacers in there now?

link to assembly drawing
http://www.yamahapartsnation.com/oemparts/a/yam/500421f0f8700209bc787460/front-wheel

 

Give us a pics of the whole front end at the wheel please. Front, and each side.

 

Thanks for the speedy response guys. I should add that the bike has been down fairly hard before; bent headlight bracket, one bolt sheared off for fender mount in left fork, one set of threads on left caliper mounts are partial. Unsure about how effed up triple tree is. Just trying to get her up and riding again with safe brakes.

550- Pretty certain everything was reinstalled as removed; will double check on "Plain Washer (14)," as I don't recall uninstalling or reinstalling that. Any idea on thickness? Thanks for the "forks were twisted," think that (or similar) might be the inherent issue here.

k-moe- see below, please let me know if you need dead-on side shots.
Head-on (a little off-center)
Right fork, left of disc:
Left fork, left of disc:

 

The top pic is off-center. I'd like to request a repeat, with the camera centerd on the centerline of the tire.

 

k-moe- here you go:

 

Wheels not centered. Forks are twisted.
Loosen the tripple-tree clamps and bounce the front end to get them to straighten up.
You can also use two straight sticks lashed perpendicular to the forks as sights. Looking down the fork from the top th forks will be straight when both sticks are parallel.

 

Thanks guys! To the garage with aplomb and a plumb (line... or sticks... or whatever.)

Appreciate the help!

 

i had the exact same problem while doing recent fork service. for me I put the wheel back on while the bars were turned full left on center stand jack under headers. so they we flopped over, and this slightly flexed every thing to the left, took me for ever to chase it down.

in the end I pulled the wheel again, and just put it back on with having the forks straight and it just worked out. maybe I got lucky and that really isn't what it was but it worked for me.

 

Not really normal here, but perhaps correct assembly order was not followed?

Good suggestions on making sure all is straight and plumb. Just wanted to add that the right disc to caliper clearance is adjustable on the 750 Seca. You can find this on page 6 of the FSM if you have one. I could not find it in the Haynes manual? Here are the instructions:

"Before tightening the pinch bolt, compress the front forks several times to make sure of proper fork operation. With the axle pinch bolt loose, work the right fork leg back and forth until the proper clearance between the disc and caliper bracket on the front wheel is obtained."

The picture in the manual shows the caliper to disc gap, and states a=a, so adjust for equal gap as stated above. I use a pair of nearly identical shims and slide them in equal distance to set the gap, then tighten the pinch bolt.

 

Had this exact problem when I took out the forks recently. If they are not properly aligned the whole assembly is skewed and not square so you will have more gap on one side than the other. Loosen up the top of the forks and straighten them like k-moe suggested.

 

Clue : fender is not lined up with wheel!
Caliper carrier must be even distance as in pic

 

Quick update- Have obtained enough gap for free wheel spin, but gap is not equal. Going to go out and pump up and down on her more today, as I'm not f*cking around with my front brakes.

 

The fender may be preventing fork alignment to be correct loosen fender bolts and move fork to give correct clearance

 

Hey- checking back in/doing my dilligence. Read up on XJCD, followed some tips.

What worked for me: pulled wheel, pulled fender, re-adjusted forks with helpful second set of eyes & tape on the bottom of axle openings. Reinstalled wheel by rolling/leaning fork ends out a bit, lowering off stands & bouncing, then torquing everything up before reinstall of fender.

Thanks for all of the help!