Problem with NCY brake on Buddy Backjack

Roofaloof · Post by **Roofaloof** » Wed Jul 17, 2013 7:06 pm

I was riding my recently acquired 2009 Blackjack and heard a loud noise when braking. It turned out one of the bolts that holds the front caliper on had fallen out!

This was because the bolt hole was stripped. Luckily the other bolt was still in place.

Stripping these bolt holes is very easy to do on the Blackjack. The bracket that holds the caliper onto the fork is made of ~1/4" thick aluminum. With only ~3 turns of engagement, it wouldn't take much torque to strip one of these holes with the M8x1.25 bolts that go into them.

To fix this, I used a Helicoil: http://www.amazon.com/Helicoil-5546-8-M ... 8+helicoil

I also Helicoiled the non-stripped hole as insurance against future damage.

The torque spec for these bolts in a normal Buddy is about 20 ft*lb. My guess is that using this torque on a Blackjack would strip these holes.

HowHH · Post by **HowHH** » Thu Jul 18, 2013 5:29 pm

Great fix! I had this problem too (posted about it back then) as did others. I thought about Helicoiling it, but ended up wimping out and getting a new bracket. Could not purchase the bracket alone. Had to purchase it as a package with a new disc ($$). Emailed Genuine about this but never received a response.

Fortunately I did not discover the problem in the way that you did. I was removing the caliper for a front tire change and one of the bolts came out way too easy. It was so stripped I couldn't even finger tighten it.

With the new plate everything torqued up to spec without stripping. I suspect that the bolts were originally overtorqued when first assembled. But I agree with you that with the thin aluminum bracket it would not take much force to strip. I wonder why they didn't just fabricate it out of steel to begin with?

I am concerned about the next tire change and whether the bracket will hold up for another assembly, so I will Helicoil the bracket as per your fix the next time it is apart. It would be good insurance.

Tocsik · Post by **Tocsik** » Thu Jul 18, 2013 5:55 pm

So, is it the NCY bracket that's thinner aluminum? Not the PGO bracket?

That's a real shame. I thought NCY was good quality.

Roofaloof · Post by **Roofaloof** » Fri Jul 19, 2013 4:34 am

I was wondering about part availability for that bracket. It's always annoying when they bundle parts like that.

Yeah, it's the NCY bracket that's thin aluminum. I don't know if the PGO part is any different in thickness or material.

koyla87 · Post by **koyla87** » Mon Sep 16, 2013 6:38 pm

i probably didn't do it properly but
when i took those same bolts out today, the top one was stripped and a bunch of locktight was in it

i was attempting to put a new front tire on, i couldn't get the brake pads separated from the wheel once it was all disconnected.
do i just wiggle the brake loose? there seems to be no space between the rim and the brake caliper....
is there a quick video somewhere? i cannot figure it out.
i already reassembled everything because i was in front of the parking lot of the motorcycle shop.

Roofaloof · Post by **Roofaloof** » Mon Sep 16, 2013 7:03 pm

Bummer!

I'd recommend using a Helicoil kit to fix both holes in the bracket like I did. Not only does it fix the damage, but it makes the threads stronger than they originally were. This is because the coil is made of stainless steel verses the aluminum of the bracket.

The only way to get the caliper off is to remove the brake disc. You can do this by removing the three allen head bolts holding the disc on.

It's a good idea to use some blue Loctite on the three disc bolts and two caliper bolts when reassembling everything.

JHScoot · Post by **JHScoot** » Fri Oct 18, 2013 9:47 am

this is good info. i will be taking a look at my brakes soon and this is a good 'heads up" i appreciate knowing as i am sure other BJ owners do. not as many of our scooters on the road so things like this could go overlooked. good to know, thanks