Maico Front Brake Problem

[Kevin Tomkyns]

 A few bad accidents have resulted here in Australia recently with Maico riders, the front brake stay comes away causing the hub to spin around and the brake actuator hits the forks
causing instant and full front wheel lock-up. Several guys have been slammed
over the bike and driven into the ground.

Obvious fix after the event would be a billet front brake hub. I was wondering if any pre-emptive fix has been done, like a possible SS insert or some form of
re-enforcement. Any views or advice on this would be appreciated and shared
with other Maico riders.

[Kevin Tomkyns]

[Kevin Tomkyns]

This is a response from Mr. John Caldwell of Canadian Maico sent to me off the list...

Hello Kevin,
First thing I see here is a part from a 76 - 77 adapted to an 82 or 82. They are not the same and should under no circumstances be adapted over. They are easily identified because there is a date code on the inside. The 81 / 84 backing plate has a reinforcing rib cast in to prevent such accidents. The long travel suspension also exerts extra force on the brake anchor and thats why its a reinforced item. Another point is magnesium is not a strong metal and over time it will deteriorate particularly where dissimilar metals are in contact. The factory never used magnesium parts over a long stretch of time. We have from time to time sold billet brake plates but not being original equipment some riders shy away from them.
Hope you find this of interest.
John Caldwell
Canadian Maico

[Doug Gardner]

Kevin, Looking at the photo it looks like the bolt was to short, could that be part of the problem? DG

[Brad van Barrelo]

It has to be metal fatigue. This makes five that I know of including me.

[Kevin Tomkyns]

This is the response from Mr. Carl Bailey of Maico Only UK sent to me off the list....

HI Kevin,

Yes it has been known to happen metals work harden etc..or can become weak over time as we know and these parts are 30 yrs old plus.. and some may have endured hard times..or just over tightening etc etc..
i keep professing to riders safety first -use new after market parts where it matters and were available we built them for those same reasons not for the fun of it to enhance the maico safety and performance ...ie.. "you only have one life" unless your a cat?
so braking areas all..

triple clamps..billet 3 pin suspension good frame welds tested etc..rust free internally gusseted properly etc
wheels and hubs the obvious really most tracks today are hard and have jumps these bikes were not designed for supercross styling or to last 30 years !!! As you know we sell the billet front two pin fixing brake plates which are strong units and actually assist in braking and ride safely and all the parts required for a safer flight..

if we can help feel free to laise

Post Script:

If guys keep riding with very old parts like stunt men & ride until it breaks etc.. maybe we should do a range of safety wear and helmets ..just a thought..

carl
maico only

[Kevin Tomkyns]

Posted off the List from Mr. Graeme Clegg U.K. Maico 490 Pilot.

Hi Kevin,
Nice to hear from you. Sorry I’ve just got back to you but I’ve been in the states on business for a while.

Regarding the front brake, I still run with the original brake plate on my 490 but after a similar slam dunk experience ( first corner after pulling the holeshot ) I fitted a s/s helicoil to mine and with a little loctite and regular checking of the bolt I’ve had no further problems.

Kind regards
Graeme

[paul]

twin bolts

[gavin williams]

Hi From South Africa
A number of Maico 490's in South Africa have experienced similar problems- it was put down to metal fatigue. I have three 490's and I have resorted to using a billet backing plate.
I am of the opinion that the magnessium gets brittle with age and hard braking can cause it to disintergrate.

[maico mad]

that happened to me also at around 80kmh doing 3 forward three sixties and as stated being slammed into the ground real bad my solution was to graft in a twin leading shoe yamaha front wheel

[Kevin Thomas Mortimer]

I have had a YZ twin leading shoe front brake for a long time. I used parts from an old Preston Petty no dive to make it fit, The brake dosen't seem to be as strong as I would like it though. My bike is a 81 490. I have a new backing plate and twin bolt stay on order from Les, but he hasn't sent it yet. Maico Only UK seem to be the only ones who have them in stock. Does anyone know of someone who makes CNC backing plates I wouldn't mind getting one made up for the YZ brake that has a similar set up to the Maico Only one. 

[Noel Harker]

as stated above the 81 mods wern,t magnesiun...only the early mods...I have had them work loose though and i found that if you locktite the correct bolt in place and then don,t undo it when changing tyres,brakes etc ..instead undo the stay at the top  where it bolts to the fork leg......haven,t had a prob since...