Not sure what it was before disassembly, but after putting new bushings on each side, I basically have zero clearance. It appears the rear swing arm bushing is dead even with the ends of the swing-arm bushings.

According to the service manual, 0.04" (1mm) clearance is recommended. I have zero and that is without the standard shims
that actually reduce the clearance.

I'm probably going to need at least one 22mm OD x 16 mm ID x 1 MM washer or two 22 x 16 x 0.5MM. Otherwise, the swing-arm is bound up.

I found some copper washers 22 x 16 x 1mm. Can't seem to locate steel ones. Opinions ? ...off to look for shim material.

Ok, the way i see it--is-- the shim is to sit over the spacer to give the end caps some protection from the fact that they are stationary & the bush ends are moving. So adding any shims there will only make things worse. In theory & if you could locate it central, a shim each end the size of the spacer would add clearance but not really practical with such a small ID & OD required. So--can you give then a pat with a flat object & a hammer. One positive pat each might drive it that little bit more required. If there's no chance then you have two options. Machine a bit off the bush face if you can get them out & back in without damaging. Or get the spacer welded up on the end or both ends & machined up tidy. Good idea to have the thin shim each end to save the end caps but i'm sure i've most likely fitted them before without the washer, but i do all sorts of dodgy stuff lol.

I don't recall if you did powdercoat but it is thick and if the end of the swingarm and frame have been coated instead of painted...then that plus maybe the new bushings are not 100% set would account for it.

That's good thinking i hadn't thought of.

below is a pic of one of the original swing-arm caps. If clearance was expected by the factory, there should be no contact by the shims that reduce the side to side play?? The cap in the picture indicates only contact at the bushing.

Yes, the inner sleeve should be slightly longer than the width of the bushings installed in the arm.

Tightening the bolt pinches the inner sleeve between the end caps so the inner sleeve can't rotate.

Shims are used if installed width of bushings is too narrow which will allow arm to slide side-to-side on sleeve.

Your installed bushing width is too wide... need to figure out how to narrow it... powdercoat thickness keeping the bushings from pressing in far enough was a great thought and likely cause.

yep, went to great length to not get powder inside the swing-arm. For whatever reason, didn't realize the clearances were that tight laterally.

going to put in steel washers as spacers pretty close to the dimensions of the inner bushing shaft and see how that works out.

If you're going to try that route, make sure OD of washer is the same or slightly smaller than OD of inner sleeve.

Hello, did you press in the bushings or heat the swingarm and freeze the bushing. The latter works best for me, seems to fully seat, I’ve had trouble on other bikes just pressing them in not quite seating.

grease and pressed.