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Author Topic: 1983 XV500 Cafe Racer  (Read 58962 times)

Offline jpmobius

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Re: 1983 XV500 Cafe Racer
« Reply #230 on: Dec 24, 2018, 20:43:27 »
It is important when examining these things to stay focused on the individual elements.  The kinematics, or mechanism of how the shock is actuated is completely unrelated to the swing arm itself.  The actual swing arm, that is the link that goes between the rear axle center and the axle center that the arm pivots on could point in any direction.  What matters is the link that goes between the pivot the swing arm rotates on and the  pivot the lower shock mount swings on.  If you align your square on this link, you will appreciate how much larger that 90o this angle is.  Obviously, since the lower shock pivot is welded onto the swing arm, the relation between the orientation of these two "links" is fixed, and so the one must depend on the other.  Perhaps it would be helpful to imagine two individual swing arms.  The one you have, and another tiny one that only goes to the shock with the two welded together.  That is actually what you have, it just does not look like it because the primary visual feature is the tube that makes up the main arm.  Your shock is not aligned with that arm, so you have to imagine what the arm that actuates the shock would look like to get a handle on the angles that are important. In fact, the tubing that makes up the arm is equally irrelevant when analyzing this (or any) system.  It of course makes sense to align the tube on centers of the "link", but think on those "banana" shaped arms needed for exhaust clearance.
 The link is still center to center, and the angle of the banana is irrelevant.  It is often quite easy to misinterpret mechanisms when the pivot centers are not directly in line with their connecting structure - you have to see past the visual illusion.  You can do this easily by making a diagram that has only the pivot centers drawn the correct distances from one another.  Do that, and you will see that the link to the shock is a long ways away from that to the axle.
« Last Edit: Dec 24, 2018, 20:46:40 by jpmobius »

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Offline Karlloss

  • Posts: 234
Re: 1983 XV500 Cafe Racer
« Reply #231 on: Dec 25, 2018, 07:54:57 »
Yes I see what you mean. The original reason for changing the lower mount was to ensure clearance between the rear wheel and shock. No that is has bags of room I will move the lower mount back and down. Live and learn hey.

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Offline Karlloss

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1983 XV500 Cafe Racer
« Reply #232 on: Jan 27, 2019, 13:54:37 »
Having listened to the views on here, I decided that I would extend the lower mount of the rear shock. So I made a soft metal clamp to grip the damper rod in the vice. I then attempted to unscrew the lower mount, but it wouldnít budge, so I apply heat, but still it wouldnít budge.

So giving up on that I decided the only way to remove the mounting eye would be to machine the mount casing until I could see the threads.

Mounting the shock on my mill, I measured the damper rod to ensure that I didnít cut to deep before exposing the threads.

So I milled to the required depth and still couldnít see any threads. I decided to go a bit further, but still no threads. Anyway after some more messing about Iíve found the reason I couldnít find the threads. The reason being is that there isnít any. It appears the lower mount/eye is fusion welded onto the rod. At first I thought it was an interference fit. But when I got another shock of the same type, it was clear to see it was only welded onto a 3mm washer.  I find this quite surprising.

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Offline Karlloss

  • Posts: 234
1983 XV500 Cafe Racer
« Reply #233 on: Feb 03, 2019, 15:03:10 »
Iíve decided to move onto getting the rest of the bike sorted as the rear suspension was taking too much time and affecting my motivation.  Although Iíve called my project a Cafe Racer, Iíve decided to make it a Brat Tracker. Iíve mounted the handle bars.

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