I just got a brand new, high-end aluminium full suspension bike and after the first ride the bottom frame linkage (the big one, near the cranks) started making loud noises (video link with sound).
After disassemblying it, i noticed that both the frame and the pivot spacer (which sits between the 2 frame contact points) were damaged, as if scrap metal was stuck in there from the factory and was grinding all along. Also, there was no lubrication/grease whatsoever: pure, rough metal-to-metal contact.
Some pictures of the issue follow:
Since the scratches were not deep (0.5mm - 1/64"), I decided to use a nail-file to smooth out both the frame and the spacer surfaces, then applied lots of grease and re-assembled the bike. It works fine but I'm not sure i've solved the problem or it's just gonna re-appear and eventually make my (new) frame unusable.
I would love to hear any opinions/ideas/solutions. I've contacted the company and my LBS but their queues are very long. Thank you very much!
Some "after" pictures follow: