I pulled the swing arm off to await the Boot to come in from RonAyers.
A note on that! Nyroc, when you say "Extremely Tight", you ain't just a whistling Dixie! When you say "Breaker Bar" you mean that too! I broke my Long handle ratchet's gear set. Had a 3 foot cheater on it and it broke into the second turn. I almost thought I was stripping a left handed thread. They put a thread locking compound on there from Hell I tell you. I thought I was going to bend the bar or break the ratchet handle before it finally moved.
Note #2 on the swing arm's pivot bearings. I called all of our bearing vendors and 2 Mfg.'s, Timken & SKF, and there are no sealed taper roller bearings out there in the swing arm pivot's size. Too bad. It would have bullet proofed them. I'll just pack them good and check them once a year unless I puncture the boot again.
OK, the other problem. I pulled the drive shaft off to inspect it and found the u-joint to be stiff on two of the pivots causing the caps to spin in the Yoke. That shaft is going to the dealer for warranty replacement tomorrow.
The autopsy on the boot shows that a stick must have forced the boot into the yoke at speed. There are tiny rubber fragments scattered inside the arm.
The job is not that bad and finding the bad U-joint and Yoke is a stroke of luck but I don't want to go in there again any sooner than I need to. I'll be finding a way to protect that boot or at least a thicker one. I am currently looking at Reducing Joining Clamps. See link McMaster Carr . It looks like the I.D.'s will be a little tight on the 4" x 3" accually 4.42" - need 4.5 or less, and 3.38" need 3.5 or less. But for $5.66 I'm gonna order one and see. It's thicker.
Gotta do something that's for sure.

 

Therock
i guess you didn't read my thread on the swingarm, they dont make a tapered bearing that is sealed, and read about installing disc to keep water out of unit and grease in. if purchasing new seals for outside, get kawi if possible if not make sure they are single lip seals, remimber to replace o rings and grease them to keep them from rolling while installing those darn bolts. if you need any more info just ask.

 

No I didn't see your post. I did a search too. Can you send or post me a link?

 

the rock
page 10 or 11 " design flaw in 650 swingarm"
Have you removed the cup yet and if you did , how did you get it out. i managed to get mine out with a long punch.Man that is a story in its self.