I would just like to convey my recent successful removal of my swing arm bushings with a cheap tool I made.
I have read about the success of the hacksaw method, filled down washers and machined multi-part tools.
I thought I'd have a go at making a tool. This tool can be made with simple hand tools and requires the sacrifice of one socket (easily replaced for less than $10).
Tools/Parts required;
Hacksaw
File
1/2" drive socket with OD of 26mm (mine was my 19mm socket)
1/2" drive extension.
Description;
This tool is a disc, made of out of a 1/2'" drive socket. This disc sits behind the bushing being removed and is hammered out using a 1/2" drive extension. The 'disc' is in two parts to enable them to be dropped through the bushing, before reassembly.
Steps;
1. Cut off the drive end of your socket. The piece you are left with should have a square hole all the way through. File flat.
(Mine was 13mm thick. In hindsight, it would probably be easier to size in step 3 if this was smaller, say 10mm).
2. Cut this piece in half the other way (you should have two C shaped pieces).
3. File the square edges round. When you look at the newly cut faces it will start to look like an oval shaped. Do this progressively until each piece of the tool can 'swing' into place without any force. If you do not do this step you will soon see why you need this relief, as you try and orient the pieces inside the swing arm tube.
4. I also filed the shoulder on my extension, to ensure a square surface for the tool to impact site. If your extension requires this ensure all four sides are even.
5. Insert the two pieces of the newly made tool behind the bushing. Orient the square filed edge away from the bushing, providing flat impact surface.
Insert the extension bar, this will force the tool back to the original 26mm. It should not be tight, there should be enough clearance that the assembly can rotate. Place the swing arm tube on a piece of wood on the ground and hit extension with suitably large hammer.
If you would like any more photos/details/measurements of the tool, let me know.
