I know that this is an old post but it has a great schematic of the rear relay arm assembly.
Any ideas on how to remove spacer #26 in the above diagram?
I have every bolt removed but this spacer is holding the relay arm in place. Any comments would be appreciated.
Canadian FJR
EDIT: Doh! Didn't see you had posted that you had it already out. Posted a whole thing on how to help. Here it is anyways.........
Mine always comes out pretty easy, but then again I completely disassemble all these suspension pivots and bearings and clean and regrease every year. Try a ton of WD40 or other solvent. If there is enough purchase a set of needle nose pliers on the outside lip to rotate it and break it loose might help.
I'm going by memory but I think what has worked for me in the past is to slide the spacer out along the bolt. (Provided it moves for you) Once the spacer is clear of the frame casting the bolt can be rotated and removed out of the way. But with the spacer in place you can't get the bolt out because of the exhaust.
The other thing that might work is getting a thin flat screwdriver (if you have one small enough) in the space between the dogbone and the frame casting and use it to push/coax the spacer out from the inside.
I dont' know if your problem is related to not being able to get things at the right angle for them to come out, or its just plain siezed.
If its just plain siezed then my general strategy is lots of solvent (WD40, penetrating oil, whatever). And I keep going back to it every day. Spray a bunch on, try and remove part. If it doesn't work come back later that night or next evening and repeat. I remember one collar I had to remove once took me about 5 days of this before it finally popped loose.
If you are _really_ skunked you might consider removing the exhaust. Its a PITA because of the extra work, but it might give you the extra space you need to work on this.
Hope this helps
Colin
