Friday, August 16, 2019

Reinforcing broken frame bracket, a new rear tire and storage option for Yagi

Follow up to my last post:

The replacement rear tire for Yagi, the 2006 Yamaha TW200 (T-Dub) arrived earlier in the day than I expected to day.

Got the old wheel off with no issues after reviewing the applicable YouTube video by tdubskid.

Note how worn down the T-Dub's rear tire had become.

Bundled the old and new tires into the trunk of the car and off I went to Performance Cycle to get the tires swapped out.  Cost?  $32.

Got the wheel with  the new tire installed with minimal hassles.  There's some slight juggling of components, and sequence is important but again, no big deal.

Then it was time to reinforce the cracked, almost broken bracket onto which the upper mount of the Cyclerack Cargo Rack mounts.

The frame bracket in question.
Not too bad, but time to reinforce it.

Bought some steel strap with 5/16" holes in it.  Cut to fit over the above bracket and modified it to still allow the use of the two smaller screw holes used by the cargo rack mount screws.

 Three bolts with corresponding washers, lock nuts and nut 
secure the steel strap  to the damaged aluminum bracket

I cleaned up the bracing I'd put in place to hold the top mounting bracket in place for the cargo rack, which had broken at the weld before.

Also added metal strapping as reinforcement

OK, so everything went back onto Yagi with only minor adjustments required to accommodate the center Hex Bolt in the middle of the steel strap.  

Gave the cargo rack a tug and it feels pretty solid; the only give is at the above picture's hold down points.

I also decided to remove the soft panniers that I'd been using on Yagi and replace it with a plain old plastic toolbox I had just laying around.  Easy to mount, fits nice, and looks OK.

 Now I have the option to carry one gallon of extra gas either
secured to the back of the top case or:

inside the top case!  Probably more secure this way.
But when I add in air compressor, jump start battery....

The weight of the gas is definitely more forward, and shouldn't cause oscillations that break things again when riding off pavement.

We'll see how this new cargo arrangement works out over the next few outings with Yagi.

Update: The metal strap in the middle broke, replaced it with small portion of same steel strap used as support, we'll see how long that lasts.


RichardM said...

The gas can in front of the box looks like the way to go. And the plastic toolbox looks good on the bike!

redlegsrides said...

Thanks RichardM, I think it’ll work fine in either position....just have to plan ahead and only take extra gas when needed.....

SonjaM said...

Storing the extra gas in the top case looks like a smart solution to me, and might be safer with regards to spillage in case your bike decides to take an unexpected nap.

redlegsrides said...

Thanks SonjaM, I think you're right. Just have to see if fumes accumulate or not while it's inside the tool box.

CCjon said...

There rebuilt bracket looks much stronger now. Hope it stands up to the vibrations.

I like how you moved the gas forward. If that gas can leaks when tipped, personally would rather have it leak onto the ground than soak everything inside the box. The contained fumes are more dangerous than the liquid. A spark from two metals hitting inside the box could cause an interesting fireworks display.

Diamond Dave said...

I think you could probably carry a lot less than a gallon of gas. The 200cc Yamaha mill should be getting you 50mpg so unless you are VERY lost, 1/2 a gallon should be plenty.

redlegsrides said...

Diamond Dave, yep, you’re correct!

redlegsrides said...

Thanks CCjon, very good points, managed to forget the can at home though this trip! Have to buy one next time I’m in civilization.