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Author Topic: How to fix your sloppy alu swing arm linkage  (Read 3846 times)
MonsterHPD
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« on: November 25, 2016, 01:48:43 PM »

When my ST2 / ST4s – based track day bike project was cancelled, I was left with some useful ST4s parts, specifically an alu swing arm to replace the M800 Dark steel item. Apart from a slight weight advantage, there is a certain bling factor,

PC120024 by torbjörn bergström, on Flickr

However, when installed, the same problem made itself obvious as with my now-sold M900: a really sloppy fit of the linkage bolt in the swing arm.

Again, with the vital access to my mates workshop facilities, I decided to do something about it. Some special tools had to be made, but nothing very special, really:
Guided countersink tool (whatever that is in English), adjustable reamer, some suitable extensions, a brass bush, and a drift for the bush.

P3040008 by torbjörn bergström, on Flickr

20161125_215952 by torbjörn bergström, on Flickr

The rest is pretty basic:
Drill out the bearing bore in the swing arm with the guided countyersink;

P3040005 by torbjörn bergström, on Flickr

P3040004 by torbjörn bergström, on Flickr

P3040003 by torbjörn bergström, on Flickr

Install the bush (no picture, I´m afraid); a couple of 100ths press fit would suffice. Heat the swing arm with some torch or heat gun (take care not to set anything on fire) and press the bush in place. Or use loc-tite if the press fit is no press.

Ream the bush, increasing the diameter a little and testing the fit with the bolt after each pass. Take care to only ever run the reamer in the “cut” direction, running it backwards will dull it.

P3060001 by torbjörn bergström, on Flickr

P3060002 (2) by torbjörn bergström, on Flickr

Clean everything up, grease in the appropriate places, assemble and enjoy your solp-free suspension linkage.
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Monster 900-2002 (sold, alive and well in the UK), 749R / 1100 HYM combo for track days, wifes / my Monster Dark 800-2003 (not entirely "Dark" anymore and a personal favourite) , 50% of 900SSie -2000 track bike for rainy days-now with tuned ST2 motor and Microtec ECU. Also parked due to having been T-boned on track.
koko64
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« Reply #1 on: December 01, 2016, 11:18:10 AM »

 waytogo
Great job.
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