Assistance needed with GL1500 Voyager installation

Hi everyone, I'm in the middle of installing a Voyager kit on my 96 Gl1500 Aspencade. I've run into a problem with the left axle bracket. Out of the box, the axle hole was too small for the fat end of the axle to pass through, so I enlarged it by about 1mm and that was enough. I removed the spacer between the caliper bracket and the swingarm per instructions (it fell out by itself). After reinstalling the axle with the newly enlarged hole and tightening the axle nut to the prescribed 80 ft-lbs, the axle bracket has a small amount of end play (same direction as axle). The upper brace for the bracket is clamped to the swingarm per instructions. The removed spacer is 3mm wide, the axle bracket is 7mm wide. I'm convinced the problem is connected to the width difference somehow.

I called MTC Voyager and talked to their Tech about the hole sizing problem. He said the holes are cut by water jet by their supplier and now and then they mess up. Problems are usually caught by the end user.

Has anyone else run into this problem? I'm not going to finish installation until I get the end play problem resolved.

If you move this thread to the outrigger forum someone there with a GL1500 and a Voyager kit might be able to help you. I have a Vulcan nomad and when I installed the kit the left axle bracket was to long where it bolted to the swing arm. I had to do some bending of the arm to make it fit. Hope someone can help.

Don

Hello everyone,

When I did my install on my 1997 GL 1500, I noticed that after the removal of the factory spacer and after installing the left side axle bracket, that I had some slight movement in the assembly.

I went to the hardware store and purchased a large thin stainless waser to take up the extra free play.

After that everything went very well.

I realy enjoy the Voyager kit.

80% satisfied with everything.

Note:

BE SURE WHEN YOU INSTALLED THE AXLE, YOU REMEMBERED TO TIGHTEN THE AXLE PINCH BOLT ON THE LEFT TRAILING ARM.

Happy Holidays to all.

[QUOTE=Gruntled;528838]Hi everyone, I'm in the middle of installing a Voyager kit on my 96 Gl1500 Aspencade. I've run into a problem with the left axle bracket. Out of the box, the axle hole was too small for the fat end of the axle to pass through, so I enlarged it by about 1mm and that was enough. I removed the spacer between the caliper bracket and the swingarm per instructions (it fell out by itself). After reinstalling the axle with the newly enlarged hole and tightening the axle nut to the prescribed 80 ft-lbs, the axle bracket has a small amount of end play (same direction as axle). The upper brace for the bracket is clamped to the swingarm per instructions. The removed spacer is 3mm wide, the axle bracket is 7mm wide. I'm convinced the problem is connected to the width difference somehow.

I called MTC Voyager and talked to their Tech about the hole sizing problem. He said the holes are cut by water jet by their supplier and now and then they mess up. Problems are usually caught by the end user.

Has anyone else run into this problem? I'm not going to finish installation until I get the end play problem resolved.[/QUOTE]