How often to lube the DSS?

[seevtsaab]

This is a part of moto maintenance I've never tackled. I'm at aboout 26K miles so figure I'm overdue.

Should I plan on replacing any bearings?

i've got the wheels off and riding is about a month away, and my woodpile is still buried in snow (another 18" expected tonight) - good time to break some stuff.

05 620

[ducpainter]

Bruce told me to do it at 24K.

I didn't need any parts. Slid the pivot out and re-lubed with synthetic grease.

Careful of the shims. There should be some on each side.

When you're re-assembling there should be no side play in the swingarm.

Shims are available.

[Slide Panda]

I just did this on my 900 the other day. Each side had two shims. One relatively thick, around 1mm, the other was very thin maybe 1/10th mm or less. So just be on look out for them.

[seevtsaab]

Sweet thanks.

[gage]

I had to remove the pinch bolts all the way on mine in order to free the shaft. I also had to machine a drift that would fit properly in the ID of the whole and bash it pretty hard with a hammer to remove.

If I recall correctly the swingarm should not be centered on the engine case and instead should be offset to one side so you may want to look into that. Best bet is to keep the existing shims from each side seperate.

[ducpainter]

<snip>

If I recall correctly the swingarm should not be centered on the engine case and instead should be offset to one side so you may want to look into that. Best bet is to keep the existing shims from each side seperate.

Not sure if it's centered or not. I think it is.

I do know you need to add 1/2 to each side if your swinger needs shimming to remove play.

[gage]

Not sure if it's centered or not. I think it is.

I do know you need to add 1/2 to each side if your swinger needs shimming to remove play.

I checked the manual and we are both right.

Here are the steps:

Insert one (1) 1.8mm shim on each side and push swingarm from right to left so that chain aligns. With a feeler gauge measure the play up to 0.10mm is ok - don't add additional shims if the feeler fits in hard. The shims are available in 0.1mm and 0.2mm if you have to add only 0.1mm make sure you add it to the right side.

The shim stacks should be even (ie Centered) or if odd the larger shim stack should be on the right. For instance if you needed .3mm a .1 would go on the left and a .2 would go on the right.

Hopefully that makes sense

edit: these #'s were for 02 S4

[Howie]

I checked the manual and we are both right.

Here are the steps:

Insert one (1) 1.8mm shim on each side and push swingarm from right to left so that chain aligns. With a feeler gauge measure the play up to 0.10mm is ok - don't add additional shims if the feeler fits in hard. The shims are available in 0.1mm and 0.2mm if you have to add only 0.1mm make sure you add it to the right side.

The shim stacks should be even (ie Centered) or if odd the larger shim stack should be on the right. For instance if you needed .3mm a .1 would go on the left and a .2 would go on the right.

Hopefully that makes sense

Makes perfect sense  The idea of using shims is to correct for manufacturing tol (or should I say lack of) ances

[csorin]

I just replaced my swingarm with a black one.  Gage is right on with the shim stack.  There will be two thick shims (1.8mm) and probably one or two .1 mm shims.  

My suggestion is to buy the manual online here:
http://www.duc.nu/manuals/

You want this one:
Workshop Manual Monster 400 620 2004

This is THE BEST 5 dollars you will spend if you plan on tearing into your Monster.  It will describe every step in detail.  My only suggestion is to bookmark the PDF file if you don't plan on printing it out.  Your 5 dollar payment allows you to download the manual three times.

Combine this with the desmotimes 2v manual and your confidence in the process will skyrocket.

[seevtsaab]

Is it neccesary to remove shock mounts or linkage rods, to free the pivot shaft, or more importantly, to
align the SA to get it back in?
I see above gage mentions aligning SA so chain aligns, which suggests the
wheel is installed (likely supported of course).
However the chain seems to restrict access to that side pinch bolt. so I see the front sprocket and clutch slave coming off.

[ducpainter]

Is it neccesary to remove shock mounts or linkage rods, to free the pivot shaft, or more importantly, to
align the SA to get it back in?
I see above gage mentions aligning SA so chain aligns, which suggests the
wheel is installed (likely supported of course).
However the chain seems to restrict access to that side pinch bolt. so I see the front sprocket and clutch slave coming off.

It's much easier with everything disconnected IMO.

The chain does restrict access to the pinch bolt.

[seevtsaab]

OK you may infer by this thread revival that I failed to complete this service last year.
This year I'm replacing the stock shock. Awesome opportunity.

Are the the swing arm shims available anyplace in particular? Generic moto item? Not listed on the
several sponsor sites I've checked. DSS 05 620.

[ducpainter]

OK you may infer by this thread revival that I failed to complete this service last year.
This year I'm replacing the stock shock. Awesome opportunity.

Are the the swing arm shims available anyplace in particular? Generic moto item? Not listed on the
several sponsor sites I've checked. DSS 05 620.

I got mine from my local dealer.

There are only a few sizes.

They measure 20.5mm id x 35.9 od. The thin ones are available in roughly .1 and .2 mm thicknesses. I think the thick ones are 1 mm

Make sure you add equal amounts to each side.

[Slide Panda]

If you've got one of the thin ones as part of your stack - dab some grease on it's face and stick it to the thick one. The thin ones are want to get away.