Installing the Modified FZ600 Swingarm
This page assumes you already have the FZ600 swing arm machined for the width, and have the FZR600 rear wheel machined for the width of the swing arm.
My swing arm was totally bare when it came back from the machinist. The first step was to install the nylon bushings and oil seals where the relay arms that connect the shock to the swing arm pivot. The bushing can be tapped in from the inside of the swing arm with a similar sized socket, and needs to be set in with enough space so that the oil seal will be flat once installed. After the bushing the oil seal gets pressed in with your finger until it is flush with the face of the swingarm tube.
Grease the pivot points on the two separate relay arms and insert them one at a time in to the holes. Once they are both in place they can be aligned and the single bolt passed through to lock them together.
I found there was a flat spot in the center of the arms which I assumed was to clear the shock. The bolt should have the head facing towards the brake caliper side of the swingarm. The swing arm is upside down on the garage floor in the shot above.
The swing arm pivots on two caged needle roller bearings at each end and the reused single RZ pivot tube which has the pivot bolt through the center. Brand new pivot bearings must be installed flush with the outside of the pivot metal.
To do this I used a large, thick washer and gently tapped the bearing in to place, checking that it was always square in the hole. When the large washer is flush with the swing arm the bearing will be too.
From either end, heavily grease the pivot tube and slide it in to place....
...followed by the shim from the original RZ (picture above is missing the swing arm pivot tube but the order of the images is correct)....
...and finally the new dust seal. Repeat the same on the other side.
I decided to use the original FZ600 chain slider so I cleaned it and installed it as shown. On the inside connection you need to use a flush bolt otherwise the wheel may rub on it.
Take the entire swingarm and place it roughly in position. If you left the chain in position, make sure that the chain loops around the pivot otherwise you'll have to either remove or replace the swingarm, or break the chain later. Make sure the shock passes through the center of the opening just after the pivot point. With a little force get the swingarm in between the two frame pivot points and slide the pivot bolt in from the right hand side. Once it is in try wiggling the end of the swingarm. There will likley be a little play from left to right. Now tighten the pivot bolt nut and check the play again. There should be none at all if the width is correct. If there is still play you can increase the amount of shims behind the dust seal and try again.