Metalikev, Most people could save time doing it your way, but Kod wanted to look inside and you have to take that bracket off to do it.

KOD, mine was different. My big swingarm gasket was made of thick black plastic. Also, I never had any rust on my collars. My 650 also never had those big thin covers either. I don't know why those are even there. All that rust was from water that came in from the inside of the housing. It either gets in from the boot or from the flaky rubber plug on the bottom. My seals look like new. So did those seal block collar thingys, so I know water came in from somewhere else.

Your seals looked really bad. I kept my seal because I think these seals would last forever if the bearings didn't go bad. I felt it would be wise to keep it in case of emergency, but it is cool that you found a way to make other seals work.

Make sure you use marine grease.

 

Hey Kiss....outstanding images.FYI...the allen is a 12mm.The only question I have is what is all the oil that seems to be inside the boot??? Or did I miss it in the thread somewhere?
02 650 camo

 

Nyroc, real welder--yes. Machinist--no. I'm just a rookie at the machining part!! I didn't do any machining on the swingarm. I did everything with a die grinder. If you ever have any profiling or grinding to do on aluminum and you can't get in there with a grinder, put a four flute 1/4 inch end mill in your die grinder, spray the aluminum with WD-40 and go to town. You'll be surprised how fast that die grinder cuts that aluminum!! You gotta have a steady hand and you really have to watch how aggressive you are with that end mill.

The rock, I got a bombproof method for removing those races. Run a bead of weld around the inside of the race and pour some water on it. It shrinks the race enough that it will fall right out. Use stick welding instead of wire and it will work every time.

KOD, if you lived anywhere near me, I'd weld it for you. It didn't take long and is the ultimate repair for what is IMO, a real crappy design flaw on Kawie's part. To Kawie's credit, the aluminum they used welded up pretty nice. If I had to do it again, I would probably cut out some aluminum discs and weld them in the tubes instead of just welding bead after bead to fill it up.

 

Thanks for the tip metallikev.

nyroc, that must be one of the differences in an early 02 and late 02 model. I bought mine in 2002 September. Mine will be exactly 2 years old this weekend. I may silicone around those plugs. Does anyone know what purpose they serve? Will you have your KQ700 by Monday? Other words are you going looking today?

deerchooper, you may get a suprise. But, if they are bad you should be able to move the swingarm side to side while jacked up.

kodiak1, that oil like substance was what worried me. Thats one of the reasons I took the brake section apart also. The oil had to have came from my rear end, the mobile 424. I looked at it last night and I know the big seal isnt leaking. I will look inside the oil fill hole tonight and see if the mobil 424 fluid has gone down any.

mastrblastr, if you could weld that up and drill those bolts on mine like you did yours I would be happy to take it all apart again. [img]i/expressions/face-icon-small-happy.gif[/img]

Going to work, talk with you this evening.

 

The KQ is not here yet. I do not know when it is coming.

I would be tempted to buy new bolts and mail them to mastr to get them drilled for zerks, but I'm not sure I'm keepin this 650 that long anyway.