Welcome, Guest. Please Login or Register

Author Topic: Cracked swing arm  (Read 1301 times)

0 Members and 1 Guest are viewing this topic.

Offline eikeboom

  • Senior Member
  • ***
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 979
Cracked swing arm
« on: December 09, 2013, 08:58:23 pm »
Hi guys
Yes, you have read it correctly - a cracked swing arm, on the sprocket side.
Saw it when I cleaned the bike after a Sunday trip:
Let's go into the mountains...there's likely to be peace and quiet
 

Offline eikeboom

  • Senior Member
  • ***
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 979
Re: Cracked swing arm
« Reply #1 on: December 09, 2013, 09:02:52 pm »
A quick search led me to threads on ADVrider and DRriders where guys have encountered the same thing. The same side, same place, same vertical crack.
 :o
Luckily it seems that it can be repaired successfully.
See photos from the web:
Let's go into the mountains...there's likely to be peace and quiet
 

Offline eikeboom

  • Senior Member
  • ***
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 979
Re: Cracked swing arm
« Reply #2 on: December 09, 2013, 09:05:50 pm »
This is how the one guy repaired it: made the shitty welds flat and had straps welded on.
I'm having the same done.
Let's go into the mountains...there's likely to be peace and quiet
 

Offline eikeboom

  • Senior Member
  • ***
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 979
Re: Cracked swing arm
« Reply #3 on: December 09, 2013, 09:08:05 pm »
These are the threads:

http://www.advrider.com/forums/showthread.php?t=28519
and
http://drriders.com/topic7065.html

It looks as if it is a weak spot in the welding.
Check your bikes out closely guys. Anybody heard of this before?
Let's go into the mountains...there's likely to be peace and quiet
 

Offline chopperpilot

  • Afrikaans...Dis my taal! Engels...Dit verstaan ek ook!
  • Forum Whore
  • ****
  • Bike: KTM 990 Adventure
    Location: Mpumalanga
  • Posts: 7,687
  • Thanked: 235 times
  • "Jack of all Trades... Master of Some."
Re: Cracked swing arm
« Reply #4 on: December 09, 2013, 10:30:53 pm »
Nog nooit van gehoor nie! Geskiedenis van jou DR? Nuut gekoop? Tipe gebruik? Sal myne gaan loer!


Sent from my iPad using Tapatalk
Current Bikes : KTM 990 R, KTM 500 XCW

End of an Era : Suzuki DR 650 SE, Husqvarna 610 TE
 

Offline eikeboom

  • Senior Member
  • ***
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 979
Re: Cracked swing arm
« Reply #5 on: December 09, 2013, 10:50:06 pm »
Ek het hom gekoop op 3500 km, alhoewel ek nooit regtig die km's geglo het nie.
Ek wheelie nie en spring heeldag bo-oor alles nie, maar ek kies wel altyd die moeilike paadjies en lyne.
 :ricky:
Miskien moet ek nou rustiger probeer ry. Of nie, die swingarm gaan nou baie sterker wees!
 :ricky:
Let's go into the mountains...there's likely to be peace and quiet
 

Offline Samou

Re: Cracked swing arm
« Reply #6 on: December 09, 2013, 10:56:14 pm »
mmmmmmm - ek kan instaan as karakter-getuie van Eikeboom - hy ry soos mens graag sou wou h jou dogter se krel moet ry met haar as pillion  :imaposer:  :peepwall:
« Last Edit: December 09, 2013, 10:56:56 pm by Samou »
Ego = 1/knowledge
 

Offline lecap

  • Moderator
  • Bachelor Dog
  • *****
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 14,847
  • Thanked: 12 times
Re: Cracked swing arm
« Reply #7 on: December 10, 2013, 09:15:46 am »
Unusual. Did not have this problem before neither on one of my DR's nor on a customers bike.


I'd probably just drill off the crack and weld it up nicely. The cracks seem to start from the mole hole at the "end" of the weld. Possibly just a welding fault, not finished off nicely, melt pool a bit too large, sags and contracts as it solidifies. The Y - shaped weld on the side panel causes internal stress as it cools down.
This will not be critical as long a the crack does not grow "around the corner" into the upper and lower panel of the box section which are the panels bearing most of the load.

I don't see the point in reinforcing the side panels of the box section since I believe the crack was caused by a combination of poor design & poor welding and not by overstressing the swing arm.
"If you think it's expensive to hire a professional to do the job, wait until you hire an amateur." (Red Adair)
 

Offline eikeboom

  • Senior Member
  • ***
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 979
Re: Cracked swing arm
« Reply #8 on: December 10, 2013, 10:40:10 pm »
It was surprisingly easy to remove the swingarm and cushion lever. After having read horror stories about seized swingarm bolts I was a bit apprehensive to start stripping. But a few sharp hammer blows to the bolt via a suitably sized wooden block got it moving - pulled it out the other end by hand.
I have to replace two bearing sets on the swingarm/cushion lever assembly that took in water - the bushes inside the needle rollers are slightly corroded. One set is underneath the swingarm where the "whishbones" connect, the other in the bottom or V of the cushion lever where the other ends of the wishbones connect.
I will also be replacing the bearing set on the swivel bolt of the swingarm - I will keep them in while the welding is being done to try and prevent distorsion there and simply replace afterwards. I think the heat will fry them.
Bearing man have all/most of the needle bearings, but not all of the bushes and seals. Will see what I can source from BMG and what from Suzuki.
« Last Edit: December 10, 2013, 10:41:11 pm by eikeboom »
Let's go into the mountains...there's likely to be peace and quiet
 

Offline eikeboom

  • Senior Member
  • ***
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 979
Re: Cracked swing arm
« Reply #9 on: December 10, 2013, 11:00:29 pm »
While I am at it I also removed the rear shock to inspect the upper bush. This removal was also no issue - I could easily get to the upper bolt past the frame and wiring loom and had to remove the exhaust and header to drop the shock out.

It looks as if the rubber has started to crack loose from the outer bush. It feels solid though. Maybe I should replace this also as everything is open now -  see the photos.

Lecap do you happen to have a stiffer rear shock spring (2nd hand) for me?
« Last Edit: December 10, 2013, 11:06:17 pm by eikeboom »
Let's go into the mountains...there's likely to be peace and quiet
 

Offline lecap

  • Moderator
  • Bachelor Dog
  • *****
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 14,847
  • Thanked: 12 times
Re: Cracked swing arm
« Reply #10 on: December 13, 2013, 08:51:33 am »
What diameter is the rubber bush? I might have a proper ball joint which fits in there. (I don't think the cracks are critical though)
I don't have a used stiffer spring. I should be able to get you a new one.
What is the free length of the spring and what are the two (different!!!) inner diameters of the ends of the spring?

How fat are you? :lol8:
"If you think it's expensive to hire a professional to do the job, wait until you hire an amateur." (Red Adair)
 

Offline eikeboom

  • Senior Member
  • ***
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 979
Re: Cracked swing arm
« Reply #11 on: December 13, 2013, 11:09:39 am »
What diameter is the rubber bush? I might have a proper ball joint which fits in there. (I don't think the cracks are critical though)
I don't have a used stiffer spring. I should be able to get you a new one.
What is the free length of the spring and what are the two (different!!!) inner diameters of the ends of the spring?

How fat are you? :lol8:

I think I'll just leave the shock bush as is, I also think it is not an issue. Suzuki's parts system doesn't show a separate component there.
I'll also leave the spring as is - no money to do unnecessary upgrades. I'm only about 80 kg and usually pack lightly.
Thanks
 :thumleft:
Let's go into the mountains...there's likely to be peace and quiet
 

Offline lecap

  • Moderator
  • Bachelor Dog
  • *****
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 14,847
  • Thanked: 12 times
Re: Cracked swing arm
« Reply #12 on: December 13, 2013, 10:43:19 pm »
For an 80 kg rider with gear and normal (10 - 15kg) stuff the OEM shock spring is fine.

As long as you don't jump table tops.

If you do that I would recommend another bike not another shock spring :biggrin:


The rubber bushes are rarely available as OEM spares. Hell you don't even get shock rebuild kits. But you can get various sizes of generics both rubber as well as the more desirable ball joints (they reduce bearing block wear considerably by eliminating bending forces on the shock).

In case of the DR650SE shock I would not worry. I only ever had one requiring a rebuild because of an oil leak and that was at 104,000km :o
"If you think it's expensive to hire a professional to do the job, wait until you hire an amateur." (Red Adair)
 

Offline eikeboom

  • Senior Member
  • ***
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 979
Re: Cracked swing arm
« Reply #13 on: January 23, 2014, 10:51:11 pm »
The repair is done and all went well.

I replaced the needle roller bearings in the swingarm pivot, available from Bearing Man. I kept the old inner races/bushes. New seals there from Suzuki.
I also replaced one set of bearings and bush in the cushion lever, available only from Suzuki.
Yamaha Helderberg pulled the old bearings for me and pressed in the new ones.

Let's go into the mountains...there's likely to be peace and quiet
 

Offline chopperpilot

  • Afrikaans...Dis my taal! Engels...Dit verstaan ek ook!
  • Forum Whore
  • ****
  • Bike: KTM 990 Adventure
    Location: Mpumalanga
  • Posts: 7,687
  • Thanked: 235 times
  • "Jack of all Trades... Master of Some."
Re: Cracked swing arm
« Reply #14 on: January 24, 2014, 10:06:38 pm »
Goed om te hoor jy's weer reisvaardig!


Sent from my iPad using Tapatalk
Current Bikes : KTM 990 R, KTM 500 XCW

End of an Era : Suzuki DR 650 SE, Husqvarna 610 TE
 

Offline eikeboom

  • Senior Member
  • ***
  • Bike: Suzuki DR650
    Location: Western Cape
  • Posts: 979
Re: Cracked swing arm
« Reply #15 on: January 24, 2014, 10:21:49 pm »
Goed om te hoor jy's weer reisvaardig!


Sent from my iPad using Tapatalk

Ek was die meeste van die vakansie perdloos. Ook maar goed, anders het ek heeltyd gatgeskuur en niks van die goed uitgerig wat ek by die huis wou doen nie!
 :ricky:
Let's go into the mountains...there's likely to be peace and quiet