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As this issue has had less than 12-hours to really sink-in...I'm still making decisions.
I'm in that weird spot where the bike is old...but has had a LOT of stuff done to it...so it's always a big decision as to how much more money to keep putting in it.
I know I'm not the only one in that situation.
Very nice looking bike !
The 3/4 inch bearing axles do not play well with the lowering blocks.
You stated that it had a Burley lowering kit.
Every time i read about a cracked axle the owner had lowering blocks and it was a 3/4 axle.
I think the 3/4 bearing axle was used from 86-99 and then a slight change in 2000/2001 to sealed 3/4 bearing axle.
I have seen several pictures and they all seem to crack at the same spot when the lowering blocks are used.
Options:
Remove lowering kit clean and weld a piece of steel on top and bottom, Tape-off and paint a similar color.
Remove lowering kit and replace with same axle.
Remove lowering kit and replace with 2002+ axle but then you have some other components to replace.
Regardless of direction you take, consider removal of lowering blocks and instead replace with different but lower shocks.
The blocks seem to alter the shock angle slightly.
you can make it stronger than stock if it's properly welded. If it were my bike, I'd do the 02 swingarm conversion, and take advantage of the significant updating.
No need for drama or fretting. Can't tell ya the number of times something similar has happened to me... the easy deal would be to have the broken one fishplated and welded, like others have said, not a really noticeable part, and properly done, will be stronger than new. Probably will not have to remove the swingarm from the bike. Trailer it to your local fabricator/welder, and he'll know what to do. Otherwise, buy that forty buck swingarm and install some updated and better bushings, knowing that it's likely it will break again in the same spot. Were it me, I'd improve and weld the old one. No need to fret and get mad, hell, things break...
Lowering blocks and 3/4" swingarms do not mix well and fractures are well documented. I have done the later swingarm conversion if you want more details.
When I had my metric before getting into harley's. I did a 250 rear tire conversion. I sent my swing-arm out to get modified to fit. They cut it and welded it back up with a step cut for more strength. They've done a ton of them this way with no issues. Just need to find someone that knows what there doing to weld yours back up for you.
Thanks for all the responses and feedback guys. Without sounding too 'mushy', I definitely appreciate being able to bounce stuff off others and get opinions that aren't affected by 'the personal stuff'. You guys offer some good insight.
Well. Tentatively. Here is the plan...
I've PM'd DanDman and hopefully will be able to work out an arrangement for the swingarm he offered. Once I have it, I can have it reinforced by a friend of mine that welds. As the bike isn't really safe to ride, I will use the downtime to pull some other parts and have them ready to powder coat...then have them all done at once.
Also, while I wait, I will be doing some research on better alternatives to the stock swingarm bushings.
I get it's not the 'end of the world'...just a pain in the butt.
I gotta toss out thanks to DanDMan. Guys like him make this Forum awesome.
Quick reply to my original post...got things worked out through a couple of e-mails and PayPal...and I had a swingarm on it's way (with a tracking number) less than 18-hours after I posted.
My 2000 rk also broke completely through. No lowering blocks. Just a weak and poor design. Found a used one. Got me back on road. When my son bought bike I insisted we strip that off and did the upgrade. Works great now. Best of luck with repair.
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