I went to a fabricator/welder. He said the light bar where it connects to the bike is only welded on one side. He said it should be welded all around. He then said he can weld gussets to the light bar and the light bracket.

I then spoke to the head of yamaha customer service. He said maybe the reason for not welding the center all around and only welding the front is so the metal does not get to hot and weaken He also said that there has to be some movement putting gussets on might make the lights to stiff and snap. I told him about others who have lost the bar or light He said his light fell off his bike. He says there is a new bar it tmight look the same but made thicker or different metal or all one peice he is not sure. He wants to see if the latest one that broke was the older model and he is checking to see if I got the newest one out as a replacement. In my heart I don't believe they changed anyting, but that is where I stand today.

Ron

I have no confidence in the bar and told him so I also explained that if anyone is injured or killed it will come out that these bars are failing and it will cost the company plenty.

The light bar is a very near imitation of the Harley lightbar....

I would love to see how Harley welded up theirs...



But looking at mine I can see..like I said.... a potential design weakness

Please keep us updated cruiser. Sounds interesting.

I just posted my own expierience with my light bar falling off today. I guess I should have read yours first. I am obviously not the only one having this problem. Do I understand you correctly that you recieved a replacement bar from Yamaha even though your bike is out of warranty?

Rsrider.... depends on what side of the bed the Yami people got up on that day. Some people get them replaced some dont. I thought I had a crack in mine..(found it early).. When I called my "stealership" they said they would replace it if it was cracked. Turned out it wasnt, it was just a fine line of something right on the weld line. But I've heard of them not helping other people. I had a valve problem with my 04' last year and got Yamaha to pay the $500 labor bill for pulling the engine out and doing the head work, I paid for the gaskets, $30. They know theres an issue with some light bars, it's just getting them to admit it and help you out. Good luck.