What Are The Causes Of Motorcycle Failures?

Manufacturers want to keep parts in production for a long time, but when there’s a problem, as Kevin Cameron explains, there must be a countermeasure.
You might wonder why I dwell on failed parts so much. Soichiro Honda said famously-and no doubt, many times-there is more to be learned from failure than success. Here, for example, is an ignition-side flywheel. You’ll see a taper and a keyway so that the ignition rotor, which is just a magnet, fits on to the taper.
As it rotates during the operation of the machine, possibly at 10,000 rpm, this whole affair can move around a bit. There can even be some slight back-and-forth movement, which is why you see reddish bands of discoloration on the taper. That is iron oxide, resulting from minute oscillatory frictional movement, which is called frettage. When you see that red powder in a joint, it means some slight motion is taking place.
This rotor is heavy, all this action is going on, and that results in stress. Stress can initiate cracking by being amplified by the presence of a defect in the metal or a sharp edge, which can act as a crack nucleation site. Here is a failed ignition rotor, and you’ll notice that the key slot is part of the failure. This kind of thing has happened to all manufacturers at various times.
When Kawasaki took its H1RW (the "W" standing for "water-cooled") Grand Prix racing in 1975, some ignition rotors broke off in just this fashion. The rotor was substantial; the taper was not. Therefore, a necessary countermeasure part: a bigger taper. This kind of thing goes on in engineering constantly.
Naturally, for reasons of common sense, we want to keep successful parts in production for a long time. That’s why each new model has as few new parts in it as can be managed. But when there’s a problem, there has to be a countermeasure. In this case, it’s simple: Make the parts stronger. It goes on all the time.
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[@paulocarreiro5855]

And yet we look with disdain at models which don't change dramatically over the course of five years. Great video and please buy the guy who edits these a beer.

[@denchua]

Goes to show the Ural was perfect from the beginning. XD

[@vintagetrikesandquads4012]

I just found your videos--I'm really enjoying them.

[@Trumplican]

I love these videos! Cameron your'e a legend to me I used to read all of your articles on Jim's dynotechresearch subscriber page! I still go back through them sometimes they are amazing reads!

[@tysoncott7402]

Love see’ing KC doing these informative vids, been a fan of yours for a long long time

[@kshitijvengurlekar1192]

Thanks.

[@trykozmaksym]

To people complaining of a background music and editing - yes, it's not your regular hands waving and trash talking CycleCruza nonsence, this place has higher concentration of knowledge and wisdom prepared so you could digest it.

[@walidassaf4276]

You may recall that I wrote to you about the engine heating problem that I had with my European bike. I was concerned about the damage that may have been done to the engine and luckily I found a buyer who was brave enough to take it off my hands. My question to you now is about how sensitive are engine parts to over heating and which parts are affected first and what are the consequences. Just how should one address the overheating problem especially when both dealer and manufacturer fail to come to the rescue.

[@povlhalberg5361]

Great video, but I have a wish, please stop this rapid editing (don't know the exact term) Let the man catch his breath and talk at his own pace... Please.

[@ronaldredman8122]

Ya more Kevin please!

[@angelocardoc]

Don't think its a problem. Kevin probably starts rambling with the camera running and the editor is just giving us what we need. Good job Kevin. Good job editor.

[@cam9868]

I don't know if you understand the formula for a popular video. It isn't long winded explanations. It's covering the information in a way the is either entertaining or informative.

[@SportbikerNZ]

A T agreed. Keep the 'rapid editing' it keeps the video focused and relevant throughout.