Thanks ol'klx-er. That's what I will do this morning. Take a peek inside and pray I get away with my lack of previous attention.

 

Ok, it was as bad if not worse than I expected. The lower rocker arm needle bearing is completely seized onto the sleeves. This is a problem area as it is constantly exposed to water during a wet ride, and clearly the factory does not grease up enough.
So now how the heck do I get this seized sleeve out without destroying something.
I tried tapping with a ball pein hammer but gave up. I will now have to order spares while waiting for advise on how to get it out of there.

 

many wheel bearings are single seal, so they can be packed from the inside if you can reach. I use double sealed bearings so the grease is sealed in

One key overlooked thing is greasing the axle - it should always have a light layer wiped on when reassembling. It will keep the axle from corroding and getting stuck in the bearings.

Last key point, seems everyone wants to pressure wash to get bikes clean. I'd rather leave mine a bit dirtier and avoid blasting chain and bearings. Unless you're going to tear apart and regrease those bearings you don't want to do any pressurized spray on them at all, including hard garden hose spray. It is too easy to blow water past the seals of bearings and the O-rings on chains.

 

Are all the needle bearings still in there?
You could at least grease them after soaking it all with a good penetrating lube and some cleaning. The lube might help with the upcoming removal and for the time being it should work...if you can get the needles cleanish and moving.
If you are missing any needle bearings or can't get them to spin after some love, then you'll need a driver to remove the bearing. An improvised tool like a bicycle head set remover would do the trick.
There are bearing kits available, supposedly with all the bearings you'd need, for $70 or so...but you're in Seychelles.
Hope this helps.
Good luck. At least you have a spare bike or two.

 

Hi Maximus, the spacer is welded in with the needles. Cannot budge the spacer. I was trying to work out how to soak that lower Rocker arm while it is still on the bike. I gave up and ordered new seals spacer and bearings from Europe via DHL. Only for one set the cost is € 45,00.plus shipping.
Anyway I will have to pull the complete rocker arm and take it to an engineering works.
Probably cost maybe 20 Dollars for an engineer to remove all the old seized up metal.
Well a lesson well learned.
For anyone reading this, it is a very simple operation to get grease packed into the needles and spacers. Pop the bike on a stand, remove the lower shock mounting and the two dog bones, slide out the spacers, pack grease and reassemble. easy 30 minute job. Or wait for it all to seize up like I did, and then you will have plenty more fun times!

 

It's all that darn salt air mist! The price you have to pay to be in the Republic of Seychelles. Tough life, but someone's gotta lead it... Graham, back in January I would have traded places gladly.