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I just had the frame and swing arm powdered on my 82 SR250...I cannot for the life of me fit the swing arm back into the frame.
The pictured right side (as you can see this is upside down) has a lip the fits into a hole in the frame and the pictured left side sits flush with the hole in the frame (obviously where the pivot shaft slides through) I just can't seem to line it up right and don't want to damage the bushes as they ain't cheap to replace!
The only variable would be the powder coating. It must be too thick on the edges of the swingarm where the bushings seat. You'll have to remove the bushings and grind down the edges..................
i had the same problem, when re-installing the swingarm. my suggestion would be to drop the engine in first and make sure it is correctly mounted (the triangular mounting tabs) which attach to the top tube of the frame need to be installed correctly for the engine and swingarm to line-up correctly.
i'm not sure why your swingarm is not fitting the slot, but i can imagine it will be pretty difficult to drop the engine in with the swingarm in place..
otherwise it could be as glenn suggested the extra thickness added by the powdercoating. just make sure you have everything double checked and be gentle with those bushes. frames also tend to tweak slightly once the engine has been removed, as it forms a part of the structural integrity of the frame.
sorry i can't be of more help, just be patient and i'm sure you'll figure it out..
Put a scissor jack between the frame rails just above where the swing arm pivot is and spread the frame. It will spring back OK as long as you don't go more than a few mm.
Unscrew the bracket and remove it, slide it onto the swingarm bush and fit them both together. Then replace the bracket screw. I've just done mine like this with no probs.
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