Midlife's 150 Swingarm Bushings
 

My buddy was kind enough to turn some UHMW (that he donated) into swingarm bushings for Midlife. These bushings are located in the swingarm (vs. the frame), and the stop point inside the tube makes bushing extraction a real pain. The OEM bushings consisted of an inner steel tube surrounded by an elastomeric material with an outer steel tube. The inner tubes had completely separated from the rubber, and not much rubber was left. The remaining outer tubes were very stubborn.

This is one of the tubes after much wrestling.

http://i158.photobucket.com/albums/t...d/DSC06340.jpg

You can see the shoulder that the bushing butts up against.

http://i158.photobucket.com/albums/t...d/DSC06342.jpg

There was a spot where the weld from the swingarm assembly penetrated a little too far into the tube. After this shot, a little work with the die grinder and a flap wheel took care of it.

http://i158.photobucket.com/albums/t...d/DSC06350.jpg

This is the UHMW material that we used. I just cut a couple of pieces off to be chucked into the lathe.

http://i158.photobucket.com/albums/t...d/DSC06343.jpg

This is the lathe that my buddy just picked up. It differs from mine in a couple of ways, most notably that it has a milling attachment. I covet it.

http://i158.photobucket.com/albums/t...d/DSC06345.jpg

This is the UHMW after a quick face cut.

http://i158.photobucket.com/albums/t...d/DSC06344.jpg

And the turning begins. Since this was my first time witnessing this process, my buddy did it in several steps for me.

http://i158.photobucket.com/albums/t...d/DSC06346.jpg

This is after all of the bulk was removed.

http://i158.photobucket.com/albums/t...d/DSC06347.jpg

It measured perfectly. I love this machine!

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My buddy then chucked a center drill into the tail stock.

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This is the perfect starting hole that results from the center drill.

http://i158.photobucket.com/albums/t...d/DSC06355.jpg

He then chucked a 1/4" bit into the tail stock...

http://i158.photobucket.com/albums/t...d/DSC06356.jpg

...followed by a 1/2" bit.

http://i158.photobucket.com/albums/t...d/DSC06357.jpg

My buddy then flipped the piece around in the chuck, quickly chopped the end off with a hacksaw, and then trimmed it to perfection. The final product.

http://i158.photobucket.com/albums/t...d/DSC06358.jpg

The final hole size is actually too small, but we didn't have the required 14mm drill bit. I'll look for one tomorrow; if I don't find one, I'll use a 9/16".

I'm anxious to see how this new bushing performs. At the very least, it will be much easier to pound out when the time comes.

that looks awesome guys .....Mrs. midlife will love the fact that her chain will stay on wile she is powering through mud or up a steep hill (these are the two area's that the chain always came off when she needed it to stay on)

Yeah, I don't expect much side play with the new bushings.

there is no emocon on here to express her happiness

I'd be happy with a beer emoticon.

Lol! Now your speaking my langauge! :lol:

I couldn't find a 14mm drill bit, so I bought the 9/16", which is 0.3mm larger. I placed a bushing in a v-block and chucked it in the vise.

http://i158.photobucket.com/albums/t...d/DSC06359.jpg

Much like the Native philosophy of building a canoe, you just trim away everything that is not a bushing.

http://i158.photobucket.com/albums/t...d/DSC06362.jpg

They fit nicely on the bolt.

http://i158.photobucket.com/albums/t...d/DSC06361.jpg

I then drilled and tapped a hole in the swingarm for a zerk.

http://i158.photobucket.com/albums/t...d/DSC06363.jpg

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A little grease and a little hydraulic pressure, and they slid right in.

http://i158.photobucket.com/albums/t...d/DSC06367.jpg

Here ya go, Midlife.

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http://i158.photobucket.com/albums/t...d/DSC06369.jpg

I'm gonna pick up some washers and jam nuts for the bolt (hopefully tomorrow), and it'll be ready for installation.

the wife said ....and I quote "COOL now I won't loose my chain" un-quote

Nice machine work! Those bushings will serve you well I'm sure :). Wonder why the chinese use such weak ones in the first place?

Cost. It costs them very little to create an elastomeric with Heaven-knows-what as the elastomer and very thin wall tube. Nobody expects these machines to last, so why would they put quality parts in them? That's where we come in. We're China Riders. :D

Very nice, hope they hold up. Let us know how they do.

I used to work in a fab/machine shop and that stuff is awsome.

more fudge is made 8)

Excellent. Are you actually gonna save some for me this time? Not that I didn't enjoy that awesome lemon meringue pie.

you betcha....well if you make it over in time that is......when is your comming over again?????? :P

I've got the parts ready now. Coming to get it, or do you want me to drop it off?

bring it by if you want fudge :)

you can see the project as well

mmmmm fudge ....tasty tasty fudge :twisted:

Sent you a text, but didn't hear from you. I know that you turn into a pumpkin after 8:30.

ya I can come over tonight if you want but don't know if the fudge will make it :wink:

got the swing arm installed but only enough room for one washer on one side

I am guessing that is why there were rubber ones?

as for making sure the two sprockets line up the only other thing I can see is to shim the sprocket over

here it is where it is always bolted (nuts and washers removed and bolts slid back)
you can see that the chain isn't quite in line

http://i58.photobucket.com/albums/g2...ar/atvs052.jpg

here is where the sprocket has to sit to be in full line with the front

http://i58.photobucket.com/albums/g2...ar/atvs053.jpg

spacer ? (2 piece preferably )

My guess is that the sprocket was never in line. As long as the chain isn't too tight, it shouldn't be an issue.

If you want to correct it, try to determine the distance that the sprocket needs to move in order to be perfect. That amount could then be cut from the left side of the swingarm for proper alignment. I wouldn't space the sprocket, because that puts it too close to the rear end housing, and it should bear against the hub.

I put it back where it is supposed to be and re-bolted it together but will give it a bit more slack in the chain as it seemed a bit tight.

now seeing as I could only get one washer on one side is the other side going to wear on the new bushing ?

going out riding tomorrow so will let you know how it works.

I wouldn't worry about it; just slather it with grease. You might not need any washers between the swingarm and the frame.

Did you ever get any fudge, Weld? :?: Inquiring minds want to know! :?

Spud :lol:

I just tore the swing arm off the new Rebel T1 and it had no washers. After taking it out there was gap that looked like a washer would fit but in fact all they did was torked the bolt so tight it sucked the frame into the swing arm tube. I added a grease fitting and threw it back on without any washers and loose enough that there was a small gap on both sides. Worked out fine and there is a place now for the grease to exit on both sides now. The swing arm moves alot better now that the frame is not binding it up on the two sides. If anything I would put a couple thin nylon washers on it.

I was thinking that nylon washers (or similar) would be a good idea as well.

I did indeed, and it was terrific! :D I managed to finish most of it on the way home, so I only had to share three pieces.

Can a zerk fitting be installed without taking it all apart?I'm scared I'm going to lose my little needle bearings when I take it apart.I have went to partskit just to see what all is involved in making up the swing bushing.I'll just have to take it apart to see what has to be done to add a zerk fitting or maybe have to add two,one on each end of the swing arm to grease each needle bearing.

One of the needle bearings on my swing arm has a piece of the rim chipped out of it,it won't spin freely like the left side bearing.I think that happened when they were pressing the bearing in there,I think the swing arm bushing is all that is holding the little needle bearings in there.I should have tried to measure the bearing while I had it apart yesterday so I could look for something better to replace them with.The other or left side appears to be okay.You might could find a sealed ball bearing to go in there.I don't know how long a sealed ball bearing would last with the lateral movement but would have to be better than what's in there.

More then likely they put it on with just a hammer and nothing else and bashed the crap out of it. Too much pressure on one side will create some hairline cracks... over time you get what you see in the picture.

If you find a replacement put a socket that is roughly the same outer diameter of the bearing and tap that with the hammer. This will give you even pressure.

I started out with nothing and still have nothing,looks like I'm holding my own.