I discovered this problem on my 2008 Windsor Tourist while overhauling the hubs last winter. (At least I assume this is the same problem) I think the problem is the dust cap becoming tightened, not loosened. Hopefully, these pictures will explain what I am talking about.
Here is a picture of the dust cap on the hub:
here is a picture of the cap off the hub:
My dust cap has been modified to fix the problem. Notice the silver piece in the center of the hub in the upper image? The dust cap rotates around that silver piece while riding. As shipped, the hub dust cap has an aluminum lip that binds the end of the hub cone and causes drag on the rotating axle. The binding only happens if the dust cap is fully tightened down. My bike was shipped to me with the dust cap loose so it didn't bind. I used a round file on my dust caps to remove that metal lip. Now the inner diameter of my dust cap at the smallest point is larger than the outer diameter of the rotating axle (as it should have been in the first place!!!!). My modified dust caps can now be fully tightened down without binding the axle.
I think it is possible for the rotating axle to cause the dust cap to self-tighten if it is dragging on it. The result could be the front wheel locking up and a bad crash. Luckily that never happened to me. When I discovered this problem, I had shivers thinking of my 40 mph downhill runs on one of my commuting routes. It could have been very bad.
I encourage anyone who owns one of these bikes to take a look at the dust cap and file it down as I did, or take it back to the dealer. It could be dangerous. The design is very poor in my opinion.
Last edited by m_yates; 05-12-09 at 11:55 AM.