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OzRob

08-04-12 10:34

XT660Z Broken rear shock cam adjustment lugs

Hi all,
I broke the rear shock on the week away trip recently, I have not seen the problem before and wondering if anyone else has seen the same problem,
The shock is fitted with a Hyperpro rear spring.
I will see if I can get a new shock under warranty as the bike has only 12000km in 6 months, however what worries me is that the lugs may break off again so I may have to MIG weld them on the sides as they only look riveted on.
http://ozrob.smugmug.com/Motorcycles...51-50110-M.jpg

http://ozrob.smugmug.com/Motorcycles...52-04929-M.jpg

Petenz

08-04-12 12:32

Quote:

Originally Posted by OzRob (Post 170834)

I wouldn't try welding them unless you strip the shock down...

Heat the oil......

Any presure in the shock will/could cause a blow out once
the metal turns molten "melts , softens under heat"....

Blistering on the inside that will/could stop the piston traveling
or sealing on the inside wall.. need honeing after welding......

Kev	08-04-12 12:32

Never seen that on a XT before, I would not tell Yamaha you were using a Hyperpro spring if you are going the warranty route.

RickM

08-04-12 12:55

I've always thought it an odd design. Well cheap I guess. Surely a threaded barrel & collar would be cheap enough to design/fit.

Would (or should) spring rate/brand really make a difference? I assume OzRob that your bike has taken one too many heavy landings??

stoic bloke

08-04-12 13:12

Hi, if it was me i would throw the original spring back in, that is, did you or your dealer fit it?. if fitted outside of the yamaha dealership, break out the spanners!

I really can't see why warranty would not cover it. the lugs are spot welded on, it's common practice and should be sufficient, yep welding potentially could be dangerous

stoic

OzRob

09-04-12 10:16

Quote:

Originally Posted by stoic bloke (Post 170838)

Hi, if it was me I would throw the original spring back in, that is, did you or your dealer fit it?. if fitted outside of the yamaha dealership, break out the spanners!

I really can't see why warranty would not cover it. the lugs are spot welded on, it's common practice and should be sufficient, yep welding potentially could be dangerous

stoic

I have put the original spring back in so it is back to standard before I take it back to the dealer tomorrow.
There is a motorcycle suspension shop down the road from the yamaha dealer, I might pop in and see if I can get some advise about welding the lugs, however they might try and sell me a Wilbers shock at twice the price I can get one for from OTR.
Thinking about it more I could make a collar that has the lugs welded onto it, and spot weld the collar onto the body of the shock, as all the weld needs to do is stop the collar from rotating.

OzRob

14-04-12 12:26

Quote:

Originally Posted by OzRob (Post 170869)

Update:
Yamaha supplied a new shock...they had one in stock...the dealer was thinking perhaps they have a known problem with the adjustment cams breaking off....anyway I decided to spot weld the lugs with the MIG welder and put the Hyperpro spring back in, so I will see how it goes.

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