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As the title says, Got the bike up on jacks etc today, managed to eventually unbolt the orig shock and linkages, did the swinger pivot bolt, and the damn thing would not come out, exhaust header in the way. Much huffing and
puffing and manged to loosen the header bolts, which alowed the exhaust to be moved out of way and get the swinger out. Great
Cleaned area up, got new swinger (all innards came with it - as its a brand
new arm), offered up the arm and bu&&£r me, it will not fit. Its too about
2-3mm too wide

So my question is, have I done something wrong or missed something out?
Has anyone else who did this have any similar problems? .

What do I do now.... This is the second weekend of working on swapping the arm. Previous one took me fm about 1200hrs to 1800hrs to get the
damn lower exhaust off and 7 cutting discs to cut the damn chain links.

I thought this job was going to be easier than its turning out to be!!

Forgive me if I've got it wrong, as I'm fairly new here too,
But I'm sure I've read that it's only Mille Swinging arms up to '03 that are a direct fit to a Falco!

I take it you are trying to fit it to a Falco ??

Some peoples slotted straight in but I've done 2 and they both were a couple of mill out.

Highly techincal description follows

You know that spacer shaped like a top hat? goes on the gearshift side i think? Well both times i ended up grinding the rim (if it were a hat )on a grinding wheel until the arm complete with spacers would fit. Theres loads of meat on it and what can it possibly effect (apart from handling, saftey and other boring stuff)

I look at it as the lesser of 2 evils as my next step was to put a bottlejack between the frame rails

Pierre wrote:Some peoples slotted straight in but I've done 2 and they both were a couple of mill out.

Highly techincal description follows

You know that spacer shaped like a top hat? goes on the gearshift side i think? Well both times i ended up grinding the rim (if it were a hat )on a grinding wheel until the arm complete with spacers would fit. Theres loads of meat on it and what can it possibly effect (apart from handling, saftey and other boring stuff)

I look at it as the lesser of 2 evils as my next step was to put a bottlejack between the frame rails

Fausto wrote:

Pierre wrote:Some peoples slotted straight in but I've done 2 and they both were a couple of mill out.

Highly techincal description follows

You know that spacer shaped like a top hat? goes on the gearshift side i think? Well both times i ended up grinding the rim (if it were a hat )on a grinding wheel until the arm complete with spacers would fit. Theres loads of meat on it and what can it possibly effect (apart from handling, saftey and other boring stuff)

I look at it as the lesser of 2 evils as my next step was to put a bottlejack between the frame rails

There should be "The Pierre Show" on TV... it would destroy the ratings

Pierre, I'm actually flabbergasted that you got so technical as to say they were both a 'a couple of mill out'. I thought it'd have been, 'they didn't fit so I hit it with a lump hammer or grinded a bit out'. Don't tell me yr turning into an engineer??

bigun wrote:Pierre, I'm actually flabbergasted that you got so technical as to say they were both a 'a couple of mill out'. I thought it'd have been, 'they didn't fit so I hit it with a lump hammer or grinded a bit out'. Don't tell me yr turning into an engineer??

Wiff a name like Pierre 'es got to prove sumfing.....innit




Good job his names not Billy

Pierre,

Thanks for the techy info mate. I think I may just have to do the same . The spacer hat rim is indeed the problem, although the others may laugh, but I did think of hitting the swinger in with a rubber mallet.

My second thought is to try and borrow or hire a hydraulic ram type thing to wident the frame a mill or so to allow the swinger to slide in. But NOT SURE if this would cause any frame damage???

I did lots of research on here and net to make sure this new Mille swinger would fit, and all pointed to a big yes , but I can't believe no one said that they had encountered problems fitting the damn thing .

Just had a thought; would a Dremmell be enough to do the job of grinding down the rim of the spacer?? As I have said before, I have never ever done anything like this sort of work on a bike before. Always used a service shop.

So any further ideas, help or hints would be most welcome indeed.
I really really need to get my bike back on the road and to ride her again, as its been months now

regards
fastrider

My second thought is to try and borrow or hire a hydraulic ram type thing to wident the frame a mill or so to allow the swinger to slide in. But NOT SURE if this would cause any frame damage???

It's always better to mill down a shim than it is to stress a critical component like the bike's frame. One mil may only be one mil, but it's enough movement to create a stress raiser along the edge of a weld, etc.

In order to 'stretch' it so it sits at a gap of an extra1 mil, you'd have to take it past that figure.

Kwackerz,

Yea I thought that, but as you rightly point out, I am worried about creating hairline stress cracks in a weld somewhere. I think I may have to get the spacer which is located on the left hand side of the swinger viewed from the rear, ground down. There is an engineering shop near where I live, they made me some bushings to allow me to use my Falco clipons on my yet to fit Ohlins forks. I'm not sure a Dremmell would be up to the job proper???

fastrider

I think it'd be hard going for a dremmel... I dont think, looking at my dremmel, that it'd cope with that sort of work, or it would, but it'd take an age to do.

Did I mention my love of Angle grinders?

I'd use one of those...

Got a machine-shop nearby with a lathe in it?

Measure up how much you need removing then go have a word with the lathe operator - he'll probably do it for a couple of pints.

Are you sure this is necessary.

I had my swingarm out last year and my memory of the components is patchy but is it possible that the spacer is being prevented from sitting fully home in the swingarm. I had issues with the O ring getting distorted and jamming between the spacer and that long tube insert (another spacer I guess) That O ring is roughly 1mm thick by the way.

Just a thought

Please do not try forcing the frame

I recall that there is a need to change the internal spacer for the Falco item as the Mille one is a bit to long.

I know there's a link to some info somewhere, I'll point you to it if I can find it.