BROKEN FRAME!! SOMEONE HELP ME!

[ABSOLUTNATI]

So I went over a large curb and heard a knock in the front of my bike (04 GS500F). I thought my windshield had came loose, but a weld had broke in the front of my frame that holds a small bracket that allows the front cowling to be attached to it. The two bolts were still attached to it though. It is where the framework of the entire front headlight fairing attaches to the main bike frame. Why would they have such a small little welds for the entire front end to rest on? Has this happened to anyone else and how did they fix it???

Here are some schematics of were it is located. It doesn't really show it though:

http://gstwins.com/photogallery/albums/userpics/17531/normal_SU-04-2005-2771%5B3%5D.gif


http://gstwins.com/photogallery/albums/userpics/17531/normal_SU-04-2005-2797%5B1%5D.gif

[dgyver]

Not the first time I have seen or heard of poor welds on a motorcycle. I have had several but not limited to the GS.

Just have the mount welded back on.

[ABSOLUTNATI]

How much should something like that run me and what kind of store should I go to?

[calamari]

those spaniards need more welding lessons  (j/k)

[ABSOLUTNATI]

My buddy said he heard of a product called "JB Weld". Does anyone have any input on this stuff, or should I stick with a professional welder?

[SmartDrug]

For something that doesn't support much of a load, JB Weld should be fine, that stuff have been used to fix cracks in engine blocks.  I haven't owned a GS-F though so if it holds more than about 20 lbs. I would consider getting it professionally done.  Either way, if I were you, I'd duct tape it together, attach everything you can to make it legal and ride to Midas, pay one of the guys there $20 cash and have him make a simple weld to the headstock, problem solved.

[Kasumi]

Welding something like that would be cheap as bloody chips, If i was even in the same country id just whip it on for free its like a 5 minute job, grind, weld, spray with some silver so no rust. Easy peasy.

Just take it to a custom metal shop or someone who is likely to have welding kit - they will slap it on for probably $20 like said before and you will be gone in 5 mins.

[ABSOLUTNATI]

Should I take the fairings off before hand, and drive it to them?

[The Buddha]

Dude no JB WELD ...
I'd make that whole thing with a muffler clamp or atleast use a muffler clamp to hold the thing back together. Post a pic, and we can try what will work.
Oh yea, its a POS.
Cool.
Srinath.

[ABSOLUTNATI]

That could be a good idea! I could get some really thick zip ties and hold it on! The only problem is that it will keep rattling onto the "turning stopper" which is attached to the yolk right below where the bracket is supposed to be. That's actually what is holding up the front fairing frame now. I went for pretty long ride last night. It basically makes a lot of rattling noise over bumps, but drives fine. I don't want to keep driving it though in case it starts to break the weld on the piece underneath (don't know the name for it "turning radius stopper"). It's  pretty thick piece though. I'll try to get some pics up here ASAP.

[ABSOLUTNATI]

I don't understand why the none of the frame microfiches show that bracket on the front. It is welded to the frame. I checked all years from 2004 on up. I actually found pictures from someone else's post showing that bracket. Picture 6-9 show the bracket. The sixth picture down shows it the best. It's right below the gauges and above the lower silver fork clamps. If I do attempt J-B Weld, do I have to remove the black paint that the frame is coated with and the rust spots, or just smear that stuff all over around the broken weld?

http://gstwins.com/gsboard/index.php?topic=38720.0

[dgyver]

So what is the big deal with it not being shown on the diagrams? They were just not updated to reflect its addition. Not like it can be ordered seperate anyway.

[GeeP]

They don't show it because it is part of the frame subassembly since it is "permanently" attached.  If you want that bracket you have to buy the frame.   

[CndnMax]

Just go find some1 with a welder and fix it up 

[ABSOLUTNATI]

There are 3 problems:

1) There is some rust on the inside of that bracket (where I think it originated from) and on some the weld breaks, as well as on the frame yolk also.

2) I think if I remove the fairings and detach the bracket from the upper fairing frame, the bracket will break even more. I see a small crack with some rust where the bolts go in.

3) I don't want an expensive or time consuming project. Taking the fairings off means undoing my aftermarket turn signal wiring. The previous owner who installed them wasn't thinking ahead. Plus, taking the fairings off doesn't give you that much more room anyways b/c of the triple tree wires and forks.

I'll ride it up to them tommorrow morning and see what they can do for at least a 2-3 year temporary fix. I'll probably sell the bike next year anyways and step up a size.

I

[pantablo]

isnt the bike new enough to be under warranty?

[dgyver]

Fix it correctly. Do not waste your time trying some kind of half-assed fix, it will only hurt any future sale.

[ABSOLUTNATI]

Took it to the metal shop my friend recommended. Ten minutes later and thirty dollars less....... DONE. They welded it fully up and down and sprayed some rubberized undercoating over it. Sooooooo relieved.