Fellow swingarm "swappers" I NEED SOME HELP!

Ive been messing with this build for a few months and im itching to get the mono rear welded up within the next few weeks.

Swingarm is off of a 01 gxsr600. Width is 9.25" at the pivot tube(the same as the stock kz swingarm)

Having a few different issues....one being this:

[img]http://[URL=http://s99.photobucket.com/user/havoc97/media/KZ%20CAFE%20BUILD/rsz_1rsz_001_zps72ac62f8.jpg.html][IMG]http://i99.photobucket.com/albums/l318/havoc97/KZ%20CAFE%20BUILD/rsz_1rsz_001_zps72ac62f8.jpg[/img][/URL][/img]

Seems like no matter what the dust caps will tweak out of position because the pivot bolt tube in the frame is so much smaller than the dust cap.

Second issue:
It seems like no matter what, even with metal spacers in there it is impossible to get all of the play out of the swingarm so it doesnt move back and forth on the pivot bolt. (yes i have a machined tube inside of the gxsr swinger to take up the gap between the stock 5/8" pivot bolt and the gxsr stock bolt.
[img][URL=http://s99.photobucket.com/user/havoc97/media/KZ%20CAFE%20BUILD/P2211488_zps1cde3643.jpg.html][IMG]http://i99.photobucket.com/albums/l318/havoc97/KZ%20CAFE%20BUILD/P2211488_zps1cde3643.jpg[/img][/URL][/img]

Even with the swinger off of the bike, if i take my hands and place them on each side of the dust cap as firm as possible, you can make the swingarm shift back and forth maybe a bit more than an eighth of an inch. The internal bearings in the arm stick just ever so slightly out past the edge of the pivot tube.

Hopefully these things make sense....I just want to get this damn issue figured out so I can move on to the suspernsion

when you click the first picture it will bring you to photobucket...click it again and you then can click the zoom button to actually see whats going on there

Generally you need to mimic the spacers that held everything on the gsxr originally. Was something retaining the seals on the gsxr? Maybe the frame flange compressed the seal/spacer? Can't tell, but it looks like your seal is integrated to the thrust washer/spacer? Does it contact the inner race of the bearing or is it just a cap that sits over the end of the tube? Looks like the inside diameter is smaller than the axle tube flange on your KZ frame allowing the seal to move? If it moves side to side it would seem your spacer isn't long enough. Perhaps you could make a new flanged spacer to take up the play and retain the seal? Takes precise measurements to get it right. Mine only has about 0.002" clearance between the tube/bearings/spacers and the width of the frame. It's a bear to put in and take out if it gets cocked.

Stop dealing in inches on a metric motorcycle, close enough does not apply when dealing with stuff like this.

5/8" = 15.875mm
The pivot bolt is in mm (15mm) not 5/8". At least you'll know what is causing the play in your swing arm after you put it together.

I used a 1997 gsxr 750 swing arm. Same exact fit as what you are going through. First of all I turned a sleeve in the lathe and pressed it into my swingarm's existing sleeve. The inside I bored out to 5/8". My pivot bolt fits nice and snug inside of my swingarm. The way I solved the problem with it sliding past the dust caps was also very simple. I essentially used large washers and welded them flush with the frame gussets. The washers are the same o.d. as the dust covers. Both problems solved. I didn't take pics of it in my build thread so I can't link you to it. Here is a similar idea as to what I did though.
kzrider.com/forum/11-projects/531667-81-kz750h-project

Oh and I may have as much slop in my pivot bolt as you do. I have only been riding my bike for about a week now and it rides smoother than it did stock. I will say I haven't had it above 50mph or so yet though.
Also I am not positive about this but, I remember measuring my pivot bolt at closer to 15.7mm which is why I bored to 5/8"

You need a washer that has a lip which puts pressure on the dust seals. You could also glue the dust seals on..

thanks for all the advice guys. here is what I ended up doing.

1" steel washers with a OD bigger than the dustcaps. Welded them in and it worked perfect. takes up the remaining "slop" i had and puts pressure on the dustcaps keeping them in place. easy fix to the problem.

[img][URL=http://s99.photobucket.com/user/havoc97/media/KZ%20CAFE%20BUILD/P5061516_zps8a4888a8.jpg.html][IMG]http://i99.photobucket.com/albums/l318/havoc97/KZ%20CAFE%20BUILD/P5061516_zps8a4888a8.jpg[/img][/URL][/img]
[img][URL=http://s99.photobucket.com/user/havoc97/media/KZ%20CAFE%20BUILD/P5061517_zpsf73b820f.jpg.html][IMG]http://i99.photobucket.com/albums/l318/havoc97/KZ%20CAFE%20BUILD/P5061517_zpsf73b820f.jpg[/img][/URL][/img]

hope the pics help anyone else who runs into this same problem.

Next up this week, finishing the mono shock conversion

Wish I could find on of these.....

www.redlinecycle.com/swingarm%20-%20direct%20fit.html

uglee wrote: Wish I could find on of these.....

www.redlinecycle.com/swingarm%20-%20direct%20fit.html

If you like that one call or PM Les Holt here on the forum. Does top notch work and will make you a swingarm to your specs
Dave

man you guys keep posting these good post. should make my swap be alot easier once i get out of this damn desert & can work on my bike.