RS Venture: Pivot Arm 2 Weld Failure

[hondo]

Has this happened to anyone else? If not, heads up!

The pivot arm (part #8FK-47332-00-00) drab green in color, that the black spring blocks are attached to, and wraps around the rear transfer rods, tore down and apart. #43 on the schematic.

Below the holes on part #43 there is a weld seam. Upon closer inspection, it appears a hair line fracture coupled with some worn shims started this whole event. It is clearly evident there was some rust in the crack which probably started the weakening process and overtime the weld seam failed.

When the pivot arm tore at the weld seam, the pivot arm braket separated and the whole suspension collapsed. It sounded like you hit a cymbal with a hammer. The springs came loose from the spring blocks, and the back end of the sled looked like a low rider.

Rolled the sled on its side could not believe what I saw.

I bent the metal bracket back up in place as best as I could. I had a thin luggage strap with me and wrapped it around the bracket and transfer rods to prevent the bracket from tearing back down. I then limped the sled (about 2 miles) back to the Lakeview Restaurant in St Agatha, Maine.

The boys at the dealership didn't know what caused the metal fatigue. They think the heavier spring that was installed to prevent two-up bottoming may have contibuted to the problem. The heavy spring was installed at 5,780 miles. The bracket failed at 7,365 miles.

I have a strong feeling that a combination of rust and a weakened weld caused the failure.

The pivot arm was covered under Yamaha's Extended Service plan.

It's hard to inspect that part of the sled on a daily basis.

There has been other discussion on the board regarding rust observed around weld seam joints.

It may be prudent to carry something with you such as duct tape, a thin strap with buckle, or some wire, so you can perform a "Maguiver" in order to prevent an extended stay in the woods.

Currently have 7,702 miles on the sled and going for 10,000 or more this year.

Just wanted to inform the board of this potential problem.

A special thanks to Maddogjeff for providing the schematic, correct terminology, and part number for me, in order to accurately write this post.

In order to veiw the schematic you must log in.

 

[aVenture]

yeap... documented.... did you read the related post last season ?

This is why they revisited 2006 bracket.

As for my 2005, this is what i have done to prevent the metal fatigue around the weld:

 

[maddogjeff]

Hondo, Looking at the schematic, did the welds fail on the top side (where the holy shock mount bracket is welded to the transfer rod holder portion) or the welds on the bottom side where the transfer rod holder wraps around?

aVenture, did a search for last season's related post but couldn't find it, any clue how to find it? Also, I know a picture is worth a thousand words, but couldn't quit tell what you did other than maybe painting it. Thanks.

 

[aVenture]

I have cranked the brightness maddogjeff... hopefully i comes out good..

The holder of the triangular ajuster(#54), is the one that fail. It is welded onto a rather thin "WrapAround" metal sheet over #44, the Alum slider.

The area around the weld moves a tiny bit each time a huge force occurs...say a big bump. What you suppose to see on the PIC is a 10mm(3/8") metal plate bended around the piece to prevent such movement and cause metal fatigue. Its bolt patern allow it to be secured from an elongated set of the #52 bolts (2), and yes i primed & painted it.

There was at least 2 count of occurence last season... 1 with stock coil and all, and one where the guy boosted the pre-loading with a custom ajuster. I think i was originally posted by "Towing", an heavy contributor of a local forum around here, Quebec.

 

[aVenture]

There is a trace on http://www.ty4stroke.com/viewtopic.php? ... c&start=30 that Towing reminds to re-enforce the bracket but could not found the original. Could be too old ? More than a year....

 

[maddogjeff]

Very nice. I now see. That makes sense since that's where all the pressure is.

Hondo, is that what broke on yours?

 

[hondo]

Hi Guys,

Just got back from riding. Did 125 miles. Current miles: 7,827.

To answer a couple questions; aVenture, I missed last years thread regarding this issue.

Maddogjeff, yes, mine failed on the top (hole side) above where aVenture has his mod. I concur with his line of thought how this fatigue occurs.

When the weld separates the suspension just "pancakes". There is nothing to hold the suspension up. That's where all the pressure is.

I'm glad to see there is also an alternative fix to this problem.

It was actually quite funny, the trail was flat with the exception of one long rolling bump. On the back side of the bump the suspension just failed without any notice. I wasn't doing more than 30 mph.

I am definitely going to have to be more vigilant inspecting this area from time-to-time.

Also,(just an assumption) with the past occurences and historical trend, Yamaha did not put up any fight in order to rectify the problem. They must know there is a problem.

Hope this helps!

 

[aVenture]

They have revisited the design on the 2006 & it looks good to me. At least on one case, the outcome could have turned into a desaster as the loose end of the coil spring rammed in the track then block the whole thing. Clearly, this was a security issue... well, still is. But not enought so for to fix the shipped sled as i see. (this is the rest of us) I did not wanted to wait how long mine would last... came up with this fix. Glad for hondo, this happened to him at the right place, speed & and time.

 

[towing]

Ok Guys, here we go...

I had mention this issue a couple of time in the last year but did not made a formal post on it here like i did on our french forum (CMIQ) in Quebec because nobody on this forum had mention this issue before ... Now you had it, so others will have it as well....

To begin, this problem only occur on the RsVenture 2005.... corrected on 2006 sleds (Yamaha know the problem...). It is the support braket of the black triangular cams that you use to adjust the rear skid spring that break and fall from the rear arm. When this happened, the rear completely fall and the spring tips usually bite in the track and lock it. Sometimes, depending at wich speed you ride when this happen, the rear end will litterally jump of a couple of foot each time the spring bite in the track before the track lock completely. The material damages are usually bent springs and teared track.

Imagine if it happen at high speed in a curve..........No need to tell you that this failure is extremely dangerous and can cause severe injury or worst...I don't understand why yamaha don't put a safety recall on this. You are the 8th case i hear from... I personnaly know 3 of them. It not seems to had injured people by now and i am glad you were not (hondo).

Now, let's talk about preventive cure... ALL 2005 RsVenture OWNERS SHOULD DO SOMETHING TO AVOID THIS PROBLEM !!!!!! There are few fix that been developed to reinforced the braket.... here are some pictures of it. The first picture show what i did on mine. The braket is made from a 1"x2" tube, it bolt on the two studs you see on the second picture For sure bullet proof. The second picture show what a bud of mine did, not as strong but will avoid the worst....

I will try to find better pictures..

Bye
Alain

 

[towing]

OK,
I had not see the picture that aVenture put, they don't appear at my first read... You have there all you need to prevent the failure....

Bye
Alain

 

[aVenture]

Towing... you must be lurking around pretty much... did'nt took that long for you to show up.....

I could have also added that to form a plate of 3/8" that size is not so easy & i had to heat it (as less as possible to keep metal property) then wrap it around a equivalent tube size then throw the whole thing into cold water. Making sure the curve would fit perfectly and touching all around but not enought for the ends to get flat on the bracket piece.... the rest of the job is one for the bolts..... high grade....fine threads...
And yes maddogjeff... it is primed & painted.

 

[Mark O]

Why is there not a recall on this????

 

[hondo]

After reading all the information you have provided, I concur, this is a serious safety issue. I will ask my dealer about it, and make a case for a safety recall.

Everyone that has an 05 RS Venture should call their respective dealer and find out their position on this issue. Yamaha certainly needs to hear about this one, if needed, over and over again.

Collectively we may be able to get something done.

Thanks to all for your responses regarding this important issue.

Please post any additional information that you may have, or discussions with your dealer.

Lets keep this thread going!

 

[hondo]

Some preliminary information:

Just called my dealer.

I presented my safety concerns and asked him to call Yamaha in order to gleen more information.

We checked part numbers:

The (05) part number is: 8FK-47332-00-00

The (06) part number is: 8ET-47332-00-00

My replacement part number is: 8ES-47332-00-00

I asked him to find out more about my replacement part.

If in fact this is a reinforced part, then everyone should have this part in order to avoid any serious injury.

He will call me back after he talks to Yamaha.

I will keep you all informed.

 

[maddogjeff]

aVenture & Towing, I took Hondo to indicate that his failure was on the other side from the adjuster bar. The side that the shock attaches to, if you look at the schematic, the top side and neither of your fixes fix that. Is that right Hondo? Is the '06 version interchangeable?