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fix for some Xj side covers

Discussion in 'XJ Technical Chat' started by ethanch, May 3, 2009.

  1. ethanch

    ethanch Member

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    I got a replacement side cover for my Seca 750 on eBay a while ago only to discover when it arrived that the bullet that plugs into the gas tank grommet was broken off. I asked around here on XJBikes about how to fix this and got several suggestions i.e. (use a screw, zip tie it, only you and your mechanic will know, etc.) all good suggestions but I couldn’t leave it alone. So here is what I came up with. I took a piece of 3/8 delrin rod, threw it in the lathe and turned a replacement bullet. I drilled a hole in the bullet mount riser right where the original used to be (don’t use a new bit, it could bite into the riser and come right out the front of your side cover before you can let go of the trigger) then mixed up some JB weld and coated the new bullet and packed some epoxy into the riser cells and the next day when the JB weld had set you couldn’t tell the difference between the original and the repair, I turned a second bullet (pictured) for just in case the bullet on the other side cover breaks off. The 3 groves set inside the mount riser and are to give the epoxy something to hold on to. Hope this helps anyone with this same problem.
     

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  2. Robert

    Robert Active Member

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    That is a great fix Ethanch. How many can you whip up to sell to those of us who don't have access to a lathe? I'd be up for at least two and a spare.

    ***Edit: What size drill bit did you use for the hole and did you eyeball the hole you drilled or did you use a jig to keep it square?
     
  3. ethanch

    ethanch Member

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    I could whip up a bunch as soon as I order more delrin from Enco, but if chacal's elves have seen this post they may already have the machinists in his toyshop knocking some out for us. (I don’t claim excusive rights to these at all, it’s a fix!) I just eyeballed the hole at 90° to the riser because I didn’t want a block or jig in my line of sight so I could keep from drilling through the front side of the cover. I used a DULL 5/16” to drill the hole, a sharp/new bit will want to grab on and fly right through the riser and cover. Even if you are off a little there is room to move the base of the bullet around to get it at 90° just make sure you center where the old one broke off. The factory cast bullets are not round, kind of egg shaped with a flat side, and they vary from 6.9mm to 8.1mm so I made mine 7.6mm+/- I will get more delrin and post when I have more.
     
  4. motorduck

    motorduck Member

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    I would buy one or two of these!
     
  5. ethanch

    ethanch Member

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    I should have some delrin this this weekend or monday, i'll start cranking some out:) Ethan
     
  6. Nighthawk

    Nighthawk Member

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    Put me down for 2...

    Keith
     
  7. 85MaximXX

    85MaximXX Member

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    also guys I put some silicone grease on the grommets to ease installation and removal. silicone grease doens't destroy the rubber and the grommets are plenty snogs even when lubed up that the covers don't fall off.
     
  8. SLKid

    SLKid Active Member

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    Hey! We sold those at Nancys Nook!!
     
  9. ethanch

    ethanch Member

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    for real or was it the larger battery powered version?;)
     
  10. SLKid

    SLKid Active Member

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    :D LOL. Stationary AND Battery-Powered. Great for commision ;p
     
  11. WesleyJN1975

    WesleyJN1975 Member

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    How much for 2 mailed to 08002?
     
  12. jgb1503

    jgb1503 Member

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    Better set up a shop, or co-op w/ chacal ;-)
     
  13. Polock

    Polock Well-Known Member

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    just a thought, if you got this, McMaster Part Number: 8587K23
    1/2 abs rod, same as the covers
    you could really glue it, nothing sticks to Delrin very well
     
  14. ethanch

    ethanch Member

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    You are right, because of the natural lubricity of delrin it does not like to stick to things, which is why I put the traction grooves in the lower part of the shaft. I just ordered some of the ABS and will see how well it machines when it gets here, thanks for the suggestion. I’ll keep everyone posted as this goes along. Ethan
     
  15. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    Actually..............I'd already been working on them, for quite some time, but it's something that never got finished.

    Maybe that method will work and hold over time, but what we discovered when we tried some plastic replacement pins is it that it would eventually break again if you just have it as a straight shaft like that. The covers don't come off "straight" out, there is always a lifting and twisting action to their removal and install, and the torque at the glued joint would eventually fail. When we tried to compensate for it by using a larger shaft, then to mount the larger shaft you had to enlarge the hole int he flange on the side cover, and then IT became the weak point.....the new peg would hold, but the flange would snap........ :evil:

    So, what we had prototyped was an aluminum, uhhh, phallic-like object 8O with a threaded shaft, and then use a metal plate on top and underneath the plastic cover mounting flange to provide security. As long as the mounting flange on the side cover is still in good shape, then it's pretty bulletproof.

    The next problem we ran into is that the, ummm, female auto-erotic 8O 8O 8O appearing devices are actually different sizes and shapes on the various different side covers, which that wasn't so much of a problem, but the size and shape of the flat attachment plates also differ.

    It was about that time that we put that project on the back-burner until some others were finished up........... :D
     
  16. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    And actually, making the "fixer" for the C-shaped ears is even more of a challenger....
     
  17. ethanch

    ethanch Member

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    Not only are you the fastest parts purveyor in the country, but you’re really funny too.
     
  18. ethanch

    ethanch Member

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    yeah, because everyones ears/tabs break off differently
     
  19. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    Shhh, don't tell anyone........
     
  20. ethanch

    ethanch Member

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    I'm going to start working on that one in a couple weeks right after I get these bullets turned out. I'll let you know how that goes. 8O
     
  21. Bushy

    Bushy Active Member

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    I fixed mine by drilling into the centre of the broken peg and putting a nail onto it with a right angle bend on the cover end, drilled a hole in the cover put the bend through it and glued the peg to the nail and cover, easy to locate in the right place, just goes right back where it came from.
     
  22. TIMEtoRIDE

    TIMEtoRIDE Active Member

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    There's an actual Yamaha part- - it's part of the 650 Turbo body mounting hardware, a nylon (white) umm- thingy with a threaded base and it comes with a nut !!
    I should take a picture. . .
     
  23. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    I don't think it's big enough to act as a side cover peg, though.......
     
  24. ethanch

    ethanch Member

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    I poured through the microfiches a few months back looking for that part and couldn’t find it. Anyway you would have to remove/cut/break out the center riser support to get a nut on the back side of the bullet riser making the riser even weaker, thus – drill a hole, insert bullet, pack JB weld into riser cells, set bullet at proper angle, let epoxy set.:)
     
  25. mozark

    mozark Member

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    I fixed mine by bending a 1/16" piece of wire in a "U" shape with a bulb at the bottom of the "U", heated the tips of the "U" to melt thru the bracket where the pin broke off, then bent the tips over so they wouldn't pull back out. Not the prettiest fix in the world, but has worked flawlessly for over 20 yrs.
     
  26. Icantinaturner

    Icantinaturner Member

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    If it can be machined, the ABS idea offered above might be a better solution over Delrin. ABS cement from Lowes plumbing section holds like iron and sets up almost instantly. If the ABS could be turned down to large 1/8" thick, washer-sized pieces for reinforcement, a dab of cement and a bit of Dremel work would fix the broken "C" problem, no? Just a thought.

    Another thought, given the (ahem) shape of the pegs and the fact that it doesn't hurt rubber, would KY jelly work better than silicon grease? :lol:
     
  27. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    Hey, now that's really out of bounds, over the limit, beyond the pale.....

    But very appropriate, all things considered. :D
     
  28. ethanch

    ethanch Member

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    I just sent Knighhawk 2 delrin bullets from the first run, the ABS came in yesterday and I will see how well it machines on Wed. when I get back out to the machine shop
     

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