Catastrophic rear brake failure

[dieseler]

Well, not sure how this happened.  But thought I would share it with everyone!

I had just finished a fairly hard ride and was heading home when all the sudden there was one of those noises that makes you pucker, followed by my brake pedal slamming up into my foot.  First thing that flashed through my mind was one of the 'golden' bolts had sheered and my linkage was going to dig into the ground and pole-vault me.  Luckily that didn't happen!  I pulled over and looked over the bike real quick, decided it was good enough to get me the couple of blocks to my house and then I parked and went on vacation.

Well, went out to the garage today to fix her up again and man!  Not sure what happened but the bolt that joints the pull rod to the drum actuator sheared ( I assume) as did the rear bolt for the locator arm.  The failure of these two parts caused pull rod to wrap itself around the rear axle!

I'm glad I wasn't on the brakes when this happened!  Now time to scrounge for replacement parts and start considering a rear-disk conversion!

Dieseler

[h2olawyer]

http://ridersofvision.net/forum/zindex.php?topic=4688.0

You must not have been paying attention.  The above topic is posted as a sticky with bold caps as a warning.

Glad you weren't hurt!  This same issue has sent bikes off the road as the tension bar acts like a pole in a pole vault.  Very dangerous situation.

Just another reminder -- if you haven't replaced the brake tension bar bolts, DO IT NOW.  The originals are 25+ years old.  They have fatigued, corroded, and otherwise weakened over time.  I've put mine on a schedule to change them whenever I put on a new rear tire.  They're inexpensive (especially when compared to the possible result of failure) & fairly easy to do with the rear wheel removed.

H₂O

[Brian Moffet]

Just go out and buy a box of 50 and keep them around.  It'll be cheaper...

Brian (who should take my own advice...)

[dieseler]

Sadly enough,  I had read that post and just hadn't got the bolts yet! ::)   Now I have no excuse (or ability) to not replace them

Dieseler

http://ridersofvision.net/forum/zindex.php?topic=4688.0

You must not have been paying attention.  The above topic is posted as a sticky with bold caps as a warning.

H₂O

[h2olawyer]

What condition are the tension bar & actuator rod in?  If it's like most when this happens, the actuator rod got wrapped around the rear hub & the tension bar got bent.  Unfortunately, I don't have any spares of those parts.  They went to inanecathode when this happened to him last year.

H₂O

[YellowJacket!]

I got two sets of the bolts from my local Yamaha dealer for 6.25 a set.  One set for me and one for Lucky.  I had to order them but they arrived in just 2 days.  The guy at the desks comment: "A Yamaha Vision?  Whats that?"  LOL

David

[kiawrench]

been there done that,, let me tell you , right now you should go kiss your bike,,, happened to me and all i had left was internal parts ,and a lot of bills .

folks ,, if you want to ride and grow old ,, check those bolts,, i added replacing them to spring wake up service,,, that way, i have it in writing  and dont forget .

[Night Vision]

maybe a two year old warning just doesn't cut anymore..... maybe the sticky should read

WARNING MUST READ AND SERIOUSLY CONSIDER SPENDING $6 TO SAVE YOUR ASS



I have another  idea..... go to that sticky and add your story...
poor 'ole Dempsey has had that spot for nearly two years...

[Lucky]

i have removed the lock so deisler can add his story...  it'll go back on after that.

--Lucky

[Night Vision]

I see Dieseler updated the thread... good job  :)

[macroars]

Anyone knowing where the diagram is?

The only thing I know, is that it not to be found at http://www.crazyasafox.com/braketensionbolts.jpg

[Ron_McCoy]

I quit using those cheesy, soft, little Yamaha brake anchor bolts years ago and use grade 8 3/8" cap screws and nylock nuts,  Do this and you won't have to worry about this anymore. Oh yeah, new nut every time it comes off.

[Tiger]

I quit using those cheesy, soft, little Yamaha brake anchor bolts years ago and use grade 8 3/8" cap screws and nylock nuts,  Do this and you won't have to worry about this anymore. Oh yeah, new nut every time it comes off.

8) Just what I've been preaching for age's...Spot on Ron 8)

                  8).......TIGER....... 8)

[ps2/bikevision]

i too found out what the brake pedal feels like when it slams up into your foot. scary. just wasn't on the vision though. was on my dirt bike a few weeks ago. i replaced all the bolts to the rear brake rod, just didn't look close enough to the brake bar, it was made of aluminium and had a crack in it. all it did was rap the brake linkage around the axle. was a real eye opener. made me glad i fixed the bolts on the vision. if it wasn't for the sticky it may of been real bad cause the front bolt on the dirtbike was loose.

[inanecathode]

I had mine break on me too, but because of my own stupidity. I threaded the tensioner nut on a few threads then went to look for a wrench. I forgot what i was doing and ended up forgetting the nut too, got about 4 miles until the bolt sheared and wrapped the linkage around the axle at 50mph. Wasnt too freaked out, it'll do what it'll do as long as you're calm everything should be ok.

[Rick G]

I've replaced the brake stay hardware several times. Now, I use grade 12.5 metric bolts and I slide a surplus 8 mm case dowel over the bolt , so it fits snugly where the step in the stock one  is . I drilled the bolt and use a castellated nut and cotter pin.

[Solo]

Hi all!

Should present myself properly, but first thing goes first. I didn't want to start a new topic about rear brake bolts, so I just add pics from my xz's ones status:



Replacement ones:



Final look:

[motoracer8]

 The sholders on the OE bolts are there for a reason, quality hardware is a good idea but you should find cap screws with a shank long enough to go through the stop bar and backing plate, sharp threads will damage aluminum.

[Rick G]

I put an 8 mm dowel pin over the bolt . it replaces the shoulder on the cheesy factory bolt . The threads on the bolt could damage the hole in the back plate and the hole is quite a bit larger than the bolt , so they take up the slack.

[Rikugun]

That's a neat trick Rick!  I use these Kawasaki brake stay bolts. The head nests in the brake backing plate, the shoulder fits the torque arm, they have provision for the safety clip pictured and have reusable metal tab lock nuts. In addition, they retain the 10 mm diameter through the threaded portion rather than being stepped down to 8mm like the stockers.   ;)  :)