P500 Safety Message Regarding the Assembly of your P5

[futzin]

I know of three P5s (one is mine, have seen another, and know of one other) whose ROPS is installed incorrectly, resulting in possible increased weakness in the event of a rollover.

The ROPS, at the two front points, may not be seated fully and correctly at its attachment points to the lower frame. The two sections should fully 'sandwich together', if you will. There should be two bolts connecting the top and bottom together at each point. (The rear attachment points are easier to see). The issue is only one bolt (the top one) is connecting them.

Visually, there should be approximately 1/2" of flat stock exposed (looking at it from the exterior). An incorrect assembly as I've described will result in about 2" of flat stock exposed. Also, a gap can be seen where the two 'half sections' do not meet.

I will attach pics, which admittedly are not very good. Hopefully @KyGal83 can share her pics again.

Please check your machines, whether P5 or not.

Correct:

Incorrect:

The cloth straps are covering much of the flat stock in the 'incorrect' pics; hopefully you get the point.

Perhaps someone can post a diagram of the correct assembly and 'pairing'.

 

[TxDoc]

Futzing...
Thank you for sharing this


Sent from my motorola edge plus 2023 using Tapatalk

 

[Hondasxs]

Am I seeing it correctly?
Looks like only 1 bolt is connecting the 2 units.
Top bolt is a false connection.
Leaving a 3rd hole below.

Sent from my SM-G996U using Tapatalk

 

[futzin]

Yes, only one bolt doing anything.

I think the bottom bolt is the one doing nothing. There is an empty hole at top in pics. That one needs to be aligned, with the top bolt in it. Bottom bolt needs to be removed and reinstalled.

 

[906UP]

This on white lightening?

 

[KyGal83]

Am I seeing it correctly?
Looks like only 1 bolt is connecting the 2 units.
Top bolt is a false connection.
Leaving a 3rd hole below.

Sent from my SM-G996U using Tapatalk

Yes, only one bolt doing anything.

I think the bottom bolt is the one doing nothing. There is an empty hole at top in pics. That one needs to be aligned, with the top bolt in it. Bottom bolt needs to be removed and reinstalled.

Yep.. Same issue as mine.

With the incorrect assembly.. one bolt is holding the ROPS to the frame on each side. The bolt is installed thru the tabs that should be on each side of the connecting tubes and not bolted thru the tubes themselves.

Let me find my pictures and I have a schematic that shows the proper installation. Be back soon.

 

[KyGal83]

Here are the schematics from the manual ..



As you can see.. the ROPS tab extending from the ROPS tube should be seated beside the frame tub and the tab from the frame should be seated beside the ROPS tube. Then all the bolt holes align and 2 bolts secure it all in place. A very sound design providing extra strength at the union.

However, Futzin new buggy, my buggy and another member here (not sure if he would like to be tagged) all had one bolt thru the tabs and NOT 2 bolts thru the tubs & tabs as designed. This creates a weak point in the attachment.

 

[KyGal83]

Here are my photos and the link to how I made my correction.

P500 - Frame / Roll Cage Adjustment on my P500

Note: Rambling write up- I will make adjustments when I sit down at the computer.. I purchased my P500 in March of 2021. I bought it used from an individual on Facebook Marketplace. I picked it up in Greenville, Tn. It had 73 miles and 13.6 hours on it. Not long after I brought it home, I...

hondasxs.com

Before (showing) the gap:


AFTER:




Before Side view showing flat tube:


After correction:

 

[futzin]

This on white lightening?

Yep

 

[futzin]

Essentially, there are 2 half tubes, or split tubes, that are not fully seated/paired together.

 

[trigger]

Here are the schematics from the manual ..

View attachment 415283View attachment 415284

As you can see.. the ROPS tab extending from the ROPS tube should be seated beside the frame tub and the tab from the frame should be seated beside the ROPS tube. Then all the bolt holes align and 2 bolts secure it all in place. A very sound design providing extra strength at the union.

However, Futzin new buggy, my buggy and another member here (not sure if he would like to be tagged) all had one bolt thru the tabs and NOT 2 bolts thru the tubs & tabs as designed. This creates a weak point in the attachment.

Didn't you say this made the machine look crooked?

 

[KyGal83]

Didn't you say this made the machine look crooked?

Yep.. because the roof and the windshield neither one would install correctly. Looked wonky.. and felt it. Always appeared it was leaning toward the passenger side.

 

[futzin]

Hers was wrong on one side only.