Removing cushion lever bearing

• Removing cushion lever bearing
  Posted by Buckeye513 on 07 May, 2013 15:59
• Anyone know any tricks or tools to use to remove the big bearing in the cushion lever? Having a hell of a time trying to get it out.
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• #1 Reply
  Posted by QuadMan8 on 07 May, 2013 17:18
• Hay Buckeye.  I ended up having to have that one taken out by the local ATV shop. I did not have a socket or bearing tool big enouch to punch it out and I didnt want to screw things up with a punch.  I tried penetrating catalysts and lots of heat but too much rust.  It was 20 bucks to have it removed--worth it to me.  I thought about trying to grind/cut the bearing but knew I would end up screwing it up.    If you can find a driver the same diamater of the bearing I would think heat and force would do the trick----im sure thats all the shop did.  good luck.   
  
  
  I even tried heating the cushon lever and quick cooling the actual bearing with a little AC reftidgerant---yES i WAS DESPERATE--no  luck.
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• #2 Reply
  Posted by Buckeye513 on 07 May, 2013 17:31
• Yeah I'm lost I've been banging on it and soaking it in penetrating lube and its not budging. Haven't added any heat or cool (I do have a fresh tank of r22 on my balcony). Thinking I might call a couple mechanics I know and see if they might have a special tool I have a buddy that has 5 snap on large chests completely full if its a specialty tool that nobody has and shops have to rent he usually owns it. Thanks for the info though hopefully somebody else will chime in with a remedy.
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• #3 Reply
  Posted by QuadMan8 on 07 May, 2013 17:59
• I definatly would try heat.  On my wheel bearings and axle carrier bearings heat made ALL the difference.  But my cushion lever bearing was a stuborn sucker for sure.
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• #4 Reply
  Posted by Dezsled on 07 May, 2013 18:08
• This is a job for a press, correctly placed supports and the right sized drivers. You may get away with removing old parts with a hammer/punch, but not installing the new parts.
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• #5 Reply
  Posted by Buckeye513 on 07 May, 2013 18:22
• Mike did you have the atv shop just press out your old bearing or did you have them install the new bearing as well after the got the old one out?
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• #6 Reply
  Posted by Dezsled on 07 May, 2013 18:42
• I had the cushion lever out when I welded up the chain guide holes in the swing arm. The grease was old but it wasn't loose, so I went to the dunes and burned the top end down.
  
  I will be going into the linkage at the same time I do the rear axle brgs.
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• #7 Reply
  Posted by SBLT500R on 07 May, 2013 19:58
• take a dremel tool with a cut off wheel, and cut a diagnal cut through the side of the bearing cage, the whole width. after you knock out the needles and cage.  then take a chisel and put it between the cage and lever, give it a few hits.  it should free the cage from the aluminum and come out.  then clean up the little bit of damage you did with a sanding drum.  don't sand the whole inside with a sanding drum, the bearing will end up being too loose.
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• #8 Reply
  Posted by QuadMan8 on 07 May, 2013 20:17
• Buckeye--I just had the bearings removed by the shop because I had the hubs, cushion, and carrier powder coated once removed.  I since got a press and bearing drivers for the install.  Just dont have time to put it together for a few more weeks.  I thought about doing what SBLT500 said but murphys law said my shaky hands would grind into the cushion lever.  Good Luck
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• #9 Reply
  Posted by Buckeye513 on 08 May, 2013 16:04
• Got the big bearing out myself today!! Now I'm stuck on the smaller front bearing it has two caps one in each side and I can't figure out how they come out. Do they push through or pull out? The manual says to use a special bearing pulling tool. I don't have that dang tool.
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• #10 Reply
  Posted by Motoman991 on 08 May, 2013 16:45
• Use a press.
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• #11 Reply
  Posted by Buckeye513 on 08 May, 2013 16:56
• It's broken so no press I guess I can take it to the machine shop up the street and have them press it out.
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• #12 Reply
  Posted by Buckeye513 on 08 May, 2013 18:48
• Also can it be pressed out according to the diagram on Honda east there's a lip in there so those washer/spacers need to come out the way they went in so I don't think they'll press through.
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• #13 Reply
  Posted by Dezsled on 08 May, 2013 18:51
• Huh.... Looks like the small bearings race (in the cushion lever) is not removable?
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• #14 Reply
  Posted by Buckeye513 on 08 May, 2013 19:21
• That's how it looks and all the needles fell out when I was pounding out the large bearing.
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• #15 Reply
  Posted by SBLT500R on 08 May, 2013 19:47
• you need to remove the 2 number 6's.  1 on each side.  a flat screw driver should pop them out.  before you can press the needle bearing outer cage out. 
  
  that bearing does have a outer cage.  if i remember right there is no cage holding the needles in, just grease.  been a few years since i rebuilt my cushion lever.
  
  heres a pic of the bearing on ebay
  
   http://www.ebay.com/itm/LT-500-R-Suzuki-New-25x32x26-Suspension-Cushion-Lever-Roller-Bearing-09263-25050-/251251132680?pt=UK_Motorcycle_Parts_13&hash=item3a7fbc0908
  
  
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• #16 Reply
  Posted by Buckeye513 on 09 May, 2013 13:15
• I tried for about three hours last night to pop the caps (#6's) out and they didn't budge. Used a flat head then tried a punch and nothing. Soaked the thing in pb blaster penetrant spray too and all the needles fell out of the bearing.
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• #17 Reply
  Posted by Q2W on 09 May, 2013 13:34
• Guess someone should of mentioned this a long time ago, but Joe Rock on here also services the cushion levers.  At least he did a few years ago.
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• #18 Reply
  Posted by QuadMan8 on 09 May, 2013 15:28
• Buckeye--I just looked at my bearings--the large cushion bearing  the needles are in a cage so they dont fall out , however on the smaller bearing you will have to apply grease and lay each bearing in one at a time.
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• #19 Reply
  Posted by Buckeye513 on 09 May, 2013 16:33
• I got the caps off the smaller front bearing and mike that entire front bearing comes out and is replaced. The caps were rusted to the ends of the bearing housing had to soak it over night in pb blaster.
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• #20 Reply
  Posted by Dezsled on 09 May, 2013 16:54
• Cool to know buck thanks for the tip. 
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• #21 Reply
  Posted by QuadMan8 on 09 May, 2013 17:08
• Buckeye--I stand corrected, I was looking at the wrong bearing.  You were referring to part number 2 in the cushion lever diagram.  I was looking at part 15 in the diagram (09263-20053 suzuki part number)  That bearing (2 of them)  are small bearings that actually go in the big  eccentric spacer.   Those bearings have loose needles held in by a little grease as I can see them scattered around the race in the bag.    Sorry for the confusion.
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• #22 Reply
  Posted by Dezsled on 09 May, 2013 17:10
• Buck can you take a pic of the cushion lever and the little brg race? Thanks
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• #23 Reply
  Posted by Buckeye513 on 09 May, 2013 17:28
• Dez I can but not till tomorrow I still haven't gotten the bearing race all the way out its getting another over night soak in pb blaster.
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• #24 Reply
  Posted by Rensch26 on 18 Jan, 2016 07:51
• I recently replaced the cushion lever bearings and I ended up ordering the correct press tools from Alpha Sports in Maine. They're a little pricey but having the correct tool made it very easy to press the old bearings out and the new bearings in. It looked like you could order a lot of original tools through their website. Just get the tool numbers from your owners manual.
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