KTM640adv Subframe fix

[Bakkie]

On a recent trip I broke my subframe due to a heavy topbox and 10km railway line. The subframe broke but I managed to do the whole trip (3days) without noticing the damage. I only noticed the damage last weekend when I lost a indicator due to the tail of the bike that started sagging. The indicator started touching the exhaust and broke-off.

Anyway I contacted Slowpoke and he was eager to help.

Remember always disconnect the battery and all other essential electrics!!!

Pics of where the frame broke






Guys with 640's will also notice that the toolkit also broke-off the frame. The piece where the toolkit was mounted must of broken off first.


I stripped the bike and then we bend the subframe back into position


and then Slowpoke started doing his thing










Then the painting started




and the finished product


After all the welding was done and paint almost dry we started connecting wires.... and we ended up with no lights on.. NOTHING 

Anyway we got the multimeter and started testing... turns out it was a ground problem on the bike..

THANKS SLOWPOKE FOR THE HELP

[Doerengone]

Neat job there.

I read of a similar failure on a 640 subframe in Australia on ADV forum.  Seems a design flaw in order to cut weight. If I had to fix I would try putting a rib in to match the existing brace on the xhorst side. Anyway, geniet hom, good as new.

[Mark Hardy]

 

very neat

[Kykdaar]

Nice fix Bakkie and Slowpoke

[SlowPoke]

Thanks to Bakkie, it was actually a very nice little project to work on! Enjoyed the last two evenings of "workshoppping" hehehe. I now know a hell of a lot more about KTM's than ever before. Was a pleasure helping dude 

We thought of putting in a flange like on the zorst side but the plastics may not have fitted. As it is the plastics (partly by some luck  ) fit around the new strut like a glove. I also welded the strut onto the subframe further back matching the last suport point of the flange on the zorst side. At least this way the frame will it it ever braks again break in a nice symmetrical way 

Next project - side pannier brackets for the 640 ?? 

[Fugly]

You had a chance to "accidentally" set the bloody thing on fire and you didn't

Good 4 you Slowpoke!

[Oupa Foe-rie]

I have a close check on the pics and could not find any evidence of beer consumption 

[SlowPoke]

Bakkie post the pics of germany's best 

[Bakkie]

 

[Oupa Foe-rie]

Ha ha ......... maybe that stuff is flammable, that's why you took it after the welding joppie 

[lecap]

grinding off the weld might look nice or inconspicuous but is a no - no

[SlowPoke]

No worries lecap... I made sure the weld is thick enough on the inside to provide support. If it does however develop a crack, I can always reweld and then leave the scar. The welding bulge on top of metal adds very little strength - strength comes from making deep welds and getting the two halves to melt together properly. But hey, we'll watch that frame closely and see