Rear Tunnel Crinkling - My Repair

[garserio]

I was ready to suggest reinforcing in the tunnel, when I read that Yami did it.

Apparently, even Yamaha's 2006 tunnel bracket addition is not enough. There is quite a bit of chatter on the apex board regarding tunnel crinkling and all the 06's have the new brackets.

My plates have held up perfectly in some VERY rough conditions that tore up the rest of my skidframe, BUT with no tunnel damage. I also tie the rear of sled down while trailering... (The jury is still out on what causes this damage...)

So, for what it's worth, my solution is standing the test of time...

 

[bluecheese]

Yamaha has agreed to look at my sled with the bent tunnel. It's at the dealer now and I'm waiting to hear back. Yamaha still claims that no one else but me has reported this problem. I find that hard to believe since the 06's all have the extra bracket behind the tunnel and the fact that replacement tunnels for the 05's are back-ordered until mid-March.

Anyone have suggestions on how to straighten the bent tunnel back out before installing the 06 brackets on an 05 sled?

 

[garserio]

Yamaha has agreed to look at my sled with the bent tunnel. It's at the dealer now and I'm waiting to hear back. Yamaha still claims that no one else but me has reported this problem. I find that hard to believe since the 06's all have the extra bracket behind the tunnel and the fact that replacement tunnels for the 05's are back-ordered until mid-March.

Anyone have suggestions on how to straighten the bent tunnel back out before installing the 06 brackets on an 05 sled?

Honestly, I think a replacement tunnel is an overboard solution considering the amount of labor involved. While the tunnel bending is complete BS on a BIG $$$ machine, it really isn't detrimental to the sled in the short term. As long as the area is flattened back out and then strengthened so it doesn't keep cycling until a fatigue fracture (My buddy calls it oil-canning... kind of like those button caps on a Snapple Bottle), then eveything should be A-OK.

I used a plastic tipped hammer and peened it out from the back side against a flat plate on the outside. Then I fabbed-up those aluminum plates and riveted them on as shown in the previous pics in this post. The repair was technically simple, just time consuming. Also, my solution covered up any artifacts from the bending. Even the best dent removal process will leave some type of visual defect, especially on shiny aluminum.

My opinion is that Yamaha should design and offer a set of plates like I made and maybe even add an extra tab that would bend around and mount onto the footwell. Also anodize them and then laser-mark the GYT logo...Then they could market them in the accessory catalog like they do for the front footwell traction plates. Some people would think, "WOW, I ride so hard, I need the rear 'snowcross support plate'... I'm such a trail riding legend. Yamaha should sponsor me..." This way at least Yamaha acknowledges the deficiency, offers a simple low copst solution and appeals to the Racer-X wannabe's out there...

Finally, I beleive there is more risk to swapping out a tunnel on your sled than getting some type of plates/brackets mounted in the bent area., even if there is still some type of visual defect left over. No one will see that when your cruising down the trail...

That's my 2 cents.

 

[Sled Dog]

Did you install one on each side? Or is only the one side buckling.

 

[bluecheese]

Mine is buckling on both sides in the exact same spot.

 

[RSVECTORFREAK]

I am thinking about getting rid of the stock exhaust now and going with the Hauck or Excell pipe to reduce rear end weight.

 

[garserio]

Did you install one on each side? Or is only the one side buckling.

I made one for each side. Both sides of my tunnel were bent.

 

[garserio]

I am thinking about getting rid of the stock exhaust now and going with the Hauck or Excell pipe to reduce rear end weight.

If all you are looking for is to stop the bending, then I'd just go with the plates to save some bucks. I think even with a lighter exhaust, the problem will still occur. However, this problem is a nice excuse to go with an Excell system, etc!

 

[milljk]

Just checked mine, same problem almost identical looking as yours. Not sure how long its been like that but I didn't notice it at the start of this year. So some time after 2600+ miles it started to occurr. Have not yet talked to the dealer about it but I'm not going to wait for them, I'll fab the plates like you did.

 

[milljk]

I have had my flap get stuck a couple times when backing up. I have the attak with tunnel stiffners and no damage on my tunnel, but the last time it happened I thought this could be how they are bending. It puts a tremendous downward pull on the tunnel when it gets stuck. I thought my flap was going to tear off it pulled down so hard. Just a thought.

Interesting thought on this from Apex side. Its possible, I have done this myself but never thought to look at tunnel for damage. I guess I will shorten my flap as well as add the brackets.

 

[RSVECTORFREAK]

I replaced mine with a short blue flap last week thinking the same thing. It can't help the rear tunnel any when this happens.

 

[RedRX1]

I was waxing my 05RX1 with 1600 mi on it and saw I have a crinkle in one side of my tunnel. Has Yami done anything for any one on this??

 

[Len Todd]

Nice work on the reinforcements. Could it be that in your rough riding, you hit once with your body-weight on the tail end of the seat (i.e. beyond where the suspension mounts)? Also, I did not see how much you weigh. That too could be a factor. I am 220 suited. I have landed my RX-1 several times on the tail end fairly hard. Once, I nearly tore off the Flap and bent the heck out of the flap support doing this. (The things jump like a lead brick, #*$&@-end heavy, and I got the bad wrists and ribs to prove it.) Yet, ... the tunnel on mine looks just fine. ?? Maybe they decreased the material thickness back there, in later models, to save weight?

 

[garserio]

Nice work on the reinforcements. Could it be that in your rough riding, you hit once with your body-weight on the tail end of the seat (i.e. beyond where the suspension mounts)? Also, I did not see how much you weigh. That too could be a factor. I am 220 suited. I have landed my RX-1 several times on the tail end fairly hard. Once, I nearly tore off the Flap and bent the heck out of the flap support doing this. (The things jump like a lead brick, #*$&@-end heavy, and I got the bad wrists and ribs to prove it.) Yet, ... the tunnel on mine looks just fine. ?? Maybe they decreased the material thickness back there, in later models, to save weight?

I weigh 175 + clothing.
I never had a tail strike.

Since I orignally posted this repair last season, I determined that the damage occurs from strapping the sled down too tight on the trailer using the rear bumper. My initial thought was that rough riding ON the trail was the culprit, but after more thought, it is clear to me that it was my rough driving TO the trail! All that bumping and jumping a trailer does as you rush to the trails going down the road is the problem. People who do not strap their rear down by using the bumper don't seem to have this problem. Anyhow, it's still a weak spot that needs to be addressed and Yamaha has indirectly admitted this defect by adding two sets of strengthening bracket on the 07's.

 

[RedRX1]

I have never strapped my sled down. I have an enclosed trailer and only use the ski tie downs.

This would have had to have happened on my last Canada trip as I had cleaned it prior and noted no damage. Usually I do saddlebag trips, but this one was based out of the Dorset area at the end of the season. No bags, mostly flat lake riding.