Relay Arm Top Mount Loose

I installed a Penske shock last week, and while doing it found that with all but the top bolt installed that the relay arm rocks back and forth. I slinged the bike with straps, took off the centerstand (grinding off the two bottom bolts) to gain access to get the top relay arm bolt out. I expected to find a mess, but everything looked really good so I lubed all the bearings up, and am preparing to reinstall. What has got me concerned is that the sleeve on the relay bolt (#26 in the photo of the fische, and in the photo of the bolt/nut) slid back allowing me to slide it to the head of the bolt and remove/install the bolt without grinding some threads off of it. The sleeve also sticks out some (see photo of bole/nut). Is it normal for the relay arm to rock back and forth, and for the sleeve to stick out? It may be just play that is needed, but it feels not normal to me like the sleeve was possibly replaced with a longer one.

If the play is normal, my time was not completely wasted as I learned how to sling the bike, the centerstand will be much easier to remove next time due to the reversed bolts, and the relay arm bearings are lubed.

Sorry for your trouble, I don't remember exactly how it goes. I did however feel the same pain. Worst part of the job IMHO! Just wanted to chime in on how DUMB Yamaha was with those bolts. Vindictive is probably more accurate. They can tell you in the manual every zip tie placement but then put those bolts in backwards... Just say'n!

Pete-o

To hopefully provide something useful for the text person who "slings" ther FJR, here is a video on how to release a ratchet strap gently:

Normal. You are all good on both counts.

As SkooterG says (Normal). Yes, the sleeve or bushing does "stick out" or protrude a bit. I found a couple posts here that verifies this (as I did myself) and others who tried to beat/pound that sleeve/bushing in believing it was causing an issue removing the relay arm when it was simply a tight fit. You're all good.

Thanks @SkooterG and @kdclaiborne for verifying this. Guess there must be some "play" in the system so it can move around without coming apart! Grease in there did not seem to be in too bad shape, but the bike is 15+ years old, so inspection and regreasing was a good idea anyway.