Fitting The Evotech Crash Protector Bobbins.

In the Kit:

Already shown on a previous page is what is comprised of in the Evotech Crash Protector Bobbin kit so this is just a reminder. There are two crash protector bobbin heads, two spacers, two 10mm washers and two M10 x 1.25mm x 90mm bolts along with the usual fitting instructions which are as follows...

1. Remove original left and right engine / frame mounting bolts.
2. Fit Evotech crash protector bobbins to both sides using the spacers, bolts and washers supplied.
3. Tighten bolts to manufacturers specification - see owners manual.

Evotech Crash Bobbin.
This is the main component that is designed to take all the impact in the event of an accident.

Evotech Crash Bobbin.

Evotech Crash Bobbin Spacer.
This component is designed to project the Bobbin away from the bike at the fixing point.

Spacer.

Evotech Crash Bobbin Washer.
This component is designed to project the Bobbins inner face when fitted with the bolt.

Washer

Evotech Crash Bobbin Bolt.
This component is used to assemble all the components using the existing threaded hole on the bike.

Bolt

Fitting Location:

The first step is to identify which bolts need to be removed for fitting the new Evotech Crash Protection bobbins. The left hand side when sitting on the bike is shown here in figure 1. Figure 2 shows what it looks like after the bobbins have been fitted. The right hand side is similar in position but obviously on the other side of the bike.

Figure 1 shows the location of the bolt, (left hand side when sat on the bike) that needs to be removed from the engine / frame to be able to mount the Evotech Crash Protector Bobbins.

Crash Bobbin Fitting Location.
Figure 1.

Figure 2 shows what the left hand side, (when sitting on the bike) looks like when the Evotech Crash Protector Bobbins are fitted into place.

Crash Bobbin Fitted.
Figure 2.

Fitting:

In the instructions it refers to removing the original cap head bolts that hold the engine to the frame from either side of the bike. I opted to do this one side at a time to minimise the possibility of misalignment to the engine although I am sure it would be perfectly OK if both sides were done simultaneously.
Using an 8mm A/F Allen key, (Figure 3) remove the original M10 x 1.25mm x 50mm cap head bolt and 10mm washer (Figure 4). Keep the bolts in a safe place in case they are required at a later date if the Evotech Crash Protector Bobbins are to be removed for some reason. .

Figure 3 shows the 8mm A/F Allen key used to remove the original engine / frame cap head bolts.

8mm A/F Allen Key.
Figure 3.

Figure 4. The original M10 x 1.25 x 50mm cap head bolt and washer that holds the engine to the frame, (2 to be removed, one either side of the bike).

M10 x 1.25 Cap head Bolt & Washer.
Figure 4.

Assembly:

Pass the washer over the bolt then pass these two units through the Bobbin Head, slide the spacer over the bolt so it locates in the recess in the bobbin head, (smallest diameter end of spacer). This is the assembly of the Evotech Crash Protector before it is fitted to the bike, (Figure 5).
Apply Loctite 243 thread retaining compound, (Figure 6) or a similar retaining compound to the threaded end of the bolt.
Using a torque wrench with an extension bar and a 17mm A/F socket, screw the bolt into the hole from where the original M10 x 1.25mm cap head bolt was removed to a torque of 55 Newton/Meters, (according to the Yamaha Service Manual).
Repeat the procedure for the opposite side.

Figure 5 shows the components from the kit in their assembled condition.

Crash Protector Assembly.
Figure 5.

Figure 6. Loctite 243 thread lock compound.

Loctite 243.
Figure 6.

Other Views:

Here are some other views showing the Evotech Crash Protector Bobbins in their fitted position.
Left hand views figure 7 and figure 8.
Right hand views figure 9 and figure 10.

Figure 7. Left hand view of assembled Evotech Crash Protector Bobbin.

Left Hand View.
Figure 7.

Figure 8. Left hand side on view of assembled Evotech Crash Protector Bobbin.

Left Hand Side On View.
Figure 8.

Figure 9. Right hand view of assembled Evotech Crash Protector Bobbin.

Right Hand View.
Figure 9.

Figure 10. Right hand side on view of assembled Evotech Crash Protector Bobbin.

Right Hand Side On View.
Figure 10.

Diagrams: For those of you who have the technology, the materials and the machinery involved, (lathe etc.) that fancy having a go at making your own Crash Protector Bobbins, here are some diagrams and measurements taken from the official Evotech Crash Protector Bobbins using a micrometer and a digital vernier caliper.	Nylon or Plastic Crash Protector Bobbins. Figure 12.
Aluminium Spacer (Painted Black Finish). Figure 11.	Nylon or Plastic Crash Protector Bobbins. Figure 12.
Anodised Steel Washer. Figure 13.	M10 x 1.25 x 90mm Steel Bolt. Figure 14.