need input on swingarm mods

greetings all, as I've received great advice here in the past I have yet
another question. I am fitting a 1987 ZX swingarm into my 1984 KZ frame. The
replacement swingarm is approx 1/4" too wide overall. My original idea was
to run it into a machine shop and have it milled down 1/8" on either end of
the pivot bolt shaft and then replace the dust caps with simple nylon
washers. Is this necessary or can I make do by simply grinding off the 1/8"
with a die or hand grinder? Just wondering how specific these tolerances
need to be as doing it by hand will probably result in a less than perfectly
square cut where the arm press's against the inside of the frame at both
sides. Am I over thinking this and is it really not a critical tolerance?


Tom B

 

I narrowed the width of the pivot area on my '77 KZ650B1 swingarm when
I converted it from a bushing to needle bearings as were used on the
'81 KZ750E2. I happened to use a surface grinder, so the sides were
very flat and parallel, but if you are careful, there is no reason why
you cannot acheive a good result. As I remember it, the frame normally
had to be sprung outward slightly to fit the swingarm, so it was always
under a little tension, which made sure there was no side play.

I would advise using power tools only with great care, do the final
removal of metal with a fine file using light strokes.

Why don't you want to use dust caps? I would advise keeping them,
to keep water out.

 

thanks for the reply Mark. The caps fit inside the swingarm, the area I
remove will be approx the entire recessed portion on each side that the
caps fit into.


Tom B
84 KZ 750/1105/ZX7 project
89 ZX6R
83 GPz550