[hpd192004]

Okay guys a little background first! I just bought my first RC in August. It is an 02 with about 16k on the motor. The bike has had a rough past with a couple wipe outs under her belt. The previous owner who is my buddy rode her really hard. He did a bunch of stunna crap and didnt really take care of her to well. Since ive had her ive fixed a few small things and installed a 15/41 520 chain kit, which i have to say is one heck of a mod. Anyways.... Ive decided to tear her down to the frame and replace as much as possible since she needs some new paint and plastic. Ive already pretty much got her all the way down. Poor thing is just hanging from my rafters in my garage. The fork seals were shot, so I removed the forks. I called some Honda dealers and they all want pretty close to 300 bucks to do just the seals. Now.... Im a loley working man with two kids, and am having a huge wedding in April so the budget is super-super tight. I called DK on the forks and he said he could do just the seals for around 100 bucks but i gotta ship em from IN to CA. Still not a bad deal. She did have a carbon fiber jardine S/O exhaust, but it was kinda beat up in spots and i do believe the can or maybee cans were leaking, so i want to replace them. I would kill for some Sato high mounts, but I just cant justify dropping 1700.00 bucks on exhaust and power commander. Ive found some good prices on high mount jardine rtONE stainless. Is this a good exhaust, and are the maps easy to find? I suppose i could take it to get Dyno'd also. Also, I was thinking of a carbon fiber air box, and ive found a couple different ones. I found one from I believe it is Thorstens for like 150.00, but it doesnt even come close to looking like the stock. Do you guys have any recommendations for this? Ive already been in contact with brett from turn one to get a new carbon intake snorket. Im planning on doing all the free mods such as pair, soft rev etc... I also am gonna clean her up really well and either refinish or replace anyparts I can get a hold of. My main question is how do you get that damn swing arm off. Ive got the back tire off, chain off, left side nut and pin removed, and shock disconnected. The only thing i can see is on the right side where the pin slides through, there seems to be some kinda sleeve in there that requires a really big allen wrench. Am i in the right direction here?? What size is this Allen head?? Ive not been able to find one this big yet. Also, what parts from the bike (unnecessary) can I remove to clean her look up a bit? Ive noticed there is a bottle(?) connected to the air box, can I remove this?? Or maybe some drain lines?? Any help you guys could give would be greatly appreaciated!! Thank You in advance. Ive included some pics for your enjoyment!!!

[Rigor]

It's not hard at all, but you'll need the Honda castle socket got the pivot retaining nuts, a chain tool for the rivet type chain link and a 14mm allen (02-up) to remove the pivot bolt.

Jack rear of bike up. (I used 2 jackstands under rear set pegs)

Remove tire/wheel.

Cut master link and remove chain.

Remove rear brake line retaining clip.

Hang brake caliper to the side. (do not disconnect)

Unbolt rear shock from lower mount on swinger.

Remove pivot retaining nuts. (castle nuts) Don't just loosen them.

Remove pivot bolt using a 14mm allen socket.

Remove the large "sleeve" that screws into frame, where pivot bolt went through. You'll need a 20mm allen socket for this. I believe this preloads the swingarm's bearings and will need to be retorqued.

If you have a bolt selection, take a bolt that has the same size head that fits in the allen. After you have one, put the threaded end in a socket and weld it in. I did that very same thing and saved myself $$ buying those specific allens. The torque rating isn't high enough to bend the soft bolts and I had some cheapo japaneese made sockets lying around.

Remove swinger and spacers. (drop down and out)

NOW.....if the swinger won't come out, loosen the engine mount bolts above the pivot, which will allow the frame to spread slightly, allowing the swinger to come out a tad easier.


Reinstall in reverse methods, but you'll need to torque the pivot bolt and castle nuts to spec, and reinstall your chain with a new rivet master link.

It only took me about an hour, and we were working at a slow, BSing pace.

The correct tools are the key....