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I purchased a 96 Xplorer 400 a couple of months ago and I've spent many nights since replacing worn out parts. It is clear that this machine was not well maintained. Every part that could wear out has worn out.

While taking off the swingarm to replace the bushings, I found that both bolts were really loose and the right one had worn away at the bolt hole in the frame. I'm thinking that I will need to weld a washer over the hole to center it again before I reassemble it.

Does anyone have any better ideas? Will the extra space created by the washer cause any issues with the other end that sits in the transmission housing?

 
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