SUMO-X Installation Instructions

240 Fat Tire Swing Arm

Step 1. Remove Stock Seat, Rear fender assembly (including stock fender struts), Rear wheel, and stock swing arm. (per Honda Service Manual).

Step 2. Mount and balance the tire to the wheel. Make sure to remove and install all components from the stock wheel unto the new wheel, which were not included in the new wheel. I.e. right bearing dust seal (should be replaced w/ new), brake rotor, final driven flange (A & B assy) and O-ring, ect.

Step 3. This step requires two people. One to hold the wheel and carefully move the swing arm into place by putting the shaft side of the swing arm in first, then aligning it to the tire. (As shown in photo 1)

Photo 1


Step 4. With one person holding the wheel and swing arm in place the second person can install the final drive (with the drive axel installed on the final drive) into the swing arm. You may have to move the swing arm up or down to get the final drive splines to line up. See photo 2. Do not have the universal joint on the drive axel at this time. Tighten the final drive nuts finger tight only at this point. The rear axel can be slid partially into place.

Photo 2




Step 5. Install the right wheel bearing collar and rear brake caliper bracket then slide the axel completely in as you go. Tighten the axel nut finger tight at this time. NOTE; to aid in this step the final drive to swing arm nuts cat be loosened and the swing arm can be adjusted slightly to aid in assembly).



Step 6. Snug swing arm to final drive bolts and axel nut. Install universal joint on the drive axel. (Grease per Honda service manual) As the swing arm assembly is aligned hold u-joint from under the swing arm and aid alignment of u-joint to transmission output shaft as the swing arm is being aligned. Align and install left pivot bolt and tighten by hand. (Left pivot bolt gets tightened first and the right pivot bolt sets pre load. This is an important step to maintain tolerance of the drive axel and the 240 swing arm.) See Honda Service Manual for torque specs.

NOTES: always support your motorcycle properly when doing mechanical work of this nature. Remember this is a heavy bike and should be blocked and secured properly!

If using a plasma or acetylene torch to cut the frame remember to safely cover fuel tank and remove the battery! SUMO-X does not recommend the use of torches for cutting the frame! Please refer to the Honda Service Manual for more lubrication and torque specifications.