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Old 09-03-2011, 12:48 PM   #1 (permalink)
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touring swingarm upgrade - photos

Here's some photos of swingarm upgrade.

The 2001 and earlier touring models have a swingarm which rotates on cleave blocks. These wear over time and allow the swingarm to twist on the swingarm pivot. Later models have spherical bearings which eliminate any twisting. In addition the later model swingarms accept a 1" rear axle and pivot on a 3/4" pivot shaft(the earlier ones have a 5/8" pivot.

To do the swap there are a number of options including buying installation kits and bushings or having the tranny machined out to accept the larger pivot shaft.

I decided against machining or reaming out the tranny as this requires specialist tools or equipment.

I decided to make my own bushes to sleeve down the new swing arm so that I could retain the 5/8" shaft.

First, out with the old swingarm. Remove mufflers, rear wheel, swingarm pivot end caps. Unscrew nut from end of pivot shaft and drift it out with a suitable length of rod.


Here's bike on lift showing bike separately supported from the tranny

Note hole in transmission for swingarm pivot



Old pivot and rubber donuts removed



Old pivot is actually larger than 5/8", never take anything for granted.



New 3/4"pivot shaft note how donuts and endplate have a slot instead of earlier hole and pin



Lathe used to make bush sleeves


Vice used to press steel sleeves into new bushes



Sleeved bushes ready for 5/8" pivot shaft



Additional sleeves to fit in spherical bearing bushes, adjustable hand reamer used to clean out sleeves to give precision fit



New model swingarm showing spherical bearings and inner bushes



My other baby



More pictures soon

Bill
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Old 09-04-2011, 09:16 AM   #2 (permalink)
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As I am retaining the original 5/8" pivot shaft it is worth noting that unlike the newer 3/4 shafts, the nut on one end of the shaft is fixed. This prevents any adjustment at that end. So that the shaft sits centrally in the tranny I had to make a small washer/spacer, although any suitable washer would have been OK.



Here's the 5/8" shaft in place in the 2007 replacement swingarm with the sleeved bushes. The lighter areas of the shaft are the sections which lie in the tranny. the central area of the shaft has a slightly smaller diameter than the rest and so does not bear against the tranny, that's why it's important to get the shaft centralised.



I used 20mm precision steel tube with 16mm inner diameter to make the sleeves. 16mm is pretty much a perfect fit for the 5/8" pivot allowing for a small amount of reaming for a precision sliding fit.

Regards

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Old 09-04-2011, 10:28 AM   #3 (permalink)
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Rear wheel and brake mods

The new swingarm accepts a 1" axle.

I want to keep the original wheel and pulley which accept a 3/4" axle. So I need to swap bearings and spacer to accept the new 1" axle. The wheel centre needs to be bored out to accept the larger bearing separator tube/sleeve/spacer.

I need to keep the original 2001 belt guard as it accepts the wide belt used on the earlier models.

The old 3/4" bearings need to be removed along with the long central 3/4" bearing-spacer tube. I used an anchor bolt as my removal tool, tightened it up and smacked it out using a long drift and big hammer.


Here's the larger spacer alongside the original


1" bearings will drop straight in but the wheel needs to be drilled out to accept the larger bearing spacer tube. I haven't decided the best way of doing it. There's plenty of meat and the spacer tube doesn't bear on the wheel surface, its purpose is to keep the bearings apart and prevent axial loads on the bearings when the axle is tightened..



The final job is to drill out the rear caliper to accept the 1" axle.

I think that covers everything. I just need to re-assemble it all. I'll do it all in one hit when I've done the wheel and brake mods, plus I'm still waiting for my 1" axle to arrive from the USA.

Regards

Bill
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Last edited by tigerbikerbill; 09-06-2011 at 06:43 AM. Reason: Clarification
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Old 09-04-2011, 02:24 PM   #4 (permalink)
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You have impressive talent Bill! Nice Job. The pics are great, thanks for posting them.
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Old 09-04-2011, 04:05 PM   #5 (permalink)
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while i admire your chutzpah for making all this trick stuff, removing the transmission really isn't that difficult, making machining it out on a mill pretty simple. You are still leaving the wimpy pivot axle. This guy here says machining out the wheels is a BAD idea.
http://www.motorcyclemetal.com/Download26.html
I'm waiting on some more parts finishing up my conversion. Actually the swing arm is done, i'm waiting on some trans/clutch goodies among other things. Good luck and thanks for the pics.
Tim
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Old 09-04-2011, 04:53 PM   #6 (permalink)
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I didnt see where he says not to machine out the wheels, I did see where he said the some people turn down the spacer to clear the hole. I bored mine out with no problem. Its just clearance.
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Old 09-05-2011, 12:16 AM   #7 (permalink)
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Great photos ! I wish I had the skills and equipment to do these kinds of things. Keep us updated on the completion if you will.
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Old 09-06-2011, 05:07 AM   #8 (permalink)
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Quote:
Originally Posted by 1bdBagr View Post
while i admire your chutzpah for making all this trick stuff, removing the transmission really isn't that difficult, making machining it out on a mill pretty simple. You are still leaving the wimpy pivot axle. This guy here says machining out the wheels is a BAD idea.
http://www.motorcyclemetal.com/Download26.html
I'm waiting on some more parts finishing up my conversion. Actually the swing arm is done, i'm waiting on some trans/clutch goodies among other things. Good luck and thanks for the pics.
Tim
I like to do my own work. I don't have a milling machine so milling out the tranny is not an option. I'm happy with a 5/8 pivot shaft.

I could have reamed out the tranny using reamers with pilot bushes but these are extremely expensive items to buy for a one off job.

I've had to make sensible compromises to achieve my goal at a reasonable cost.

As for the wheel, the part which will be enlarged is not under stress and is not a bearing surface. As Chipmaker said, it's only clearance. The spacer touches only the axle itself and the inner race of the two wheel bearings. Boring it out is not an issue. In fact, later wheel castings (2002 onwards) are identical but have been machined out to accept the larger spacer, so what's the difference?

Thank you to everybody for your kind remarks and encouragement. I'll continue to post photos as the project nears completion.

Regards

Bill
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Old 09-06-2011, 06:06 AM   #9 (permalink)
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Nice job and pics, thanks.
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Old 09-18-2011, 11:39 AM   #10 (permalink)
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rob

Hi nice work,i did the same a few years ago but i took a 3/4 rear axle and have it drilled out to 5/8,and after 20k miles it works just fine
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Old 09-29-2011, 10:05 PM   #11 (permalink)
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Bill, OUTSTANDING! Your skills are very impressive. as you know I still have my Touring Link on my 03 and I replaced all three mounts including the doughnuts so it is very good, for now. We will see how well they hold up. Eagerly awaiting update to answer question, "How stable in fast bumpy sweepers?" By the way that Triumph looks sweet, it must haul ass! Aren't they 2300 cc? Comp Cams, the company that sella the Velva ride engine mount (not to be confused with the Vulva Ride mount, also a sweeet ride) sells a replacement turnbuckle that encases the adjusting rod in urethane which supposedly further isolates the vibes from engine to the frame. Can't find reviews on them though.
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Old 09-30-2011, 10:59 PM   #12 (permalink)
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Quote:
Originally Posted by coastie56 View Post
Bill, OUTSTANDING! Your skills are very impressive. as you know I still have my Touring Link on my 03 and I replaced all three mounts including the doughnuts so it is very good, for now. We will see how well they hold up. Eagerly awaiting update to answer question, "How stable in fast bumpy sweepers?" By the way that Triumph looks sweet, it must haul ass! Aren't they 2300 cc? Comp Cams, the company that sella the Velva ride engine mount (not to be confused with the Vulva Ride mount, also a sweeet ride) sells a replacement turnbuckle that encases the adjusting rod in urethane which supposedly further isolates the vibes from engine to the frame. Can't find reviews on them though.
Coastie, your avatar looks like the real-life me. I'm not joking.

The Triumph is awesome. It's like a Road king on serious steroids. 2.3 litres and handles like a dream. I did my European tour on it this year. The Harley will get left in the garage more often than it is used to. The Ultra is more comfortable but it can't hold a candle to the Triumph in performance terms.

My rim is being reamed out as I write.
Hopefully I'll post some more photos soon with my thoughts on how the mods have improved the ride.

Bill
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Old 10-01-2011, 02:45 AM   #13 (permalink)
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OMG everybody says I also resemble Shultz! Also "I know nuthink!" LOL Post pictures of mods, not your rim!
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Old 12-22-2011, 09:53 AM   #14 (permalink)
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OK - a little more progress. I had difficulty finding a machine shop to enlarge the wheel centre to take the larger spacer for the 1" axle.

So I cheated and bought a used wheel. Here it is with the pulley and disc fixed in place.

I broke two 45 torx bits getting the disc off of the old wheel. Those screws were in mega tight. I had to get my propane torch on them to loosen the loctite then they came out more easily without any further tool breakage.




I decided to fit a new tyre to the rim. I use furniture polish to lubricate the tyre edge to help it slip over the rim. Rim protectors limit scratches caused by the levers










Here's the new swingarm in position on the bike



You can see the swingarm spindle waiting for the donut and locknut



Donut in place




That's all for today. Next I need to fit the end caps and get the wheel in place. More photos soon.

Bill
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Old 12-22-2011, 10:49 AM   #15 (permalink)
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Road King Cole is reading this now saying WTF is this? Road King Cole is reading this now saying WTF is this?
great thread TBB!

The pic's make the changing of the tire look easy...

rkc
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