'05 GS Frame Crack!

[AndyR34]

Did a quick search on here for frame cracking on '05 standard 1200GSs and saw one or two with the same problem that I found on mine last week...

Right hand side small angle bracket that attaches to the rear of the gearbox, cracked right through but a little surface rust on one side so it has obviously not happened overnight. The bike is a June 2005 model with 28,000km (none of which have been on anything other than tarmac or metalled roads!).

Popped into my local dealer and asked what they recommend. Considering the fact that it is almost two years out of warranty what do you reckon they said???? Just how much does a new frame go for from BWM?

Would be interested to hear peoples own experiences of frame cracking issues and what they reckon is my next step......

Andy

 

[Pukmeister]

 

[AndyR34]

Other cases!

I am sure the Spanish BWM owners site won't mind me using their photo, mine is excatly the same crack/position!

Please see:

http://www.bmwmotos.com/cgi-bin/yabb2/YaBB.pl?num=1208120528

Andy

 

[Phil Clarke]

I bet that the bracket was welded on slightly out of alignment during manufacture and its cracked after a few years of heating / cooling and work hardening. Your best bet will be to grind out the crack and weld it up, preferably in situ. Make sure you completely disconnect the battery before hand and clib the negative side of the welder as close to the crack as possible.

 

[AndyR34]

My lucky day (well, nearly!!!)

Actually, my dealer (Kirsche Motorrad in Moenchengladbach) is going to pay for the whole frame, yep, even though it is 24 months out of warranty, and all I will have to pay is the labour. I thought Great, until I realised the scale of the job...

They reckon it's a 5 hour job so should cost me about 440Euros, which I suppose isn't too bad......considering!

Not sure what the outcome of the other 'out of warranty' cracking cases were but as things go, I'm not too bad off.

And now for a pint before telling the long-haired General!!

Opinions???

TTFN

Andy

 

[spock]

Opinions???

TTFN

Andy

have it welded,

 

[Uinneag]

Get the new frame powder coated before assembly

 

[(RIP) Bin Ridin]

Weld it but reserve right to change later if any doubt or recurrence.

 

[vtwinmad]

Hello , have you had a new clutch fitted ? or had the gearbox removed , the reason is , there is a sequence to the re - tightening of the sub frame bolts , do it wrong and that bracket will fail .

 

[david a hall]

Weld it, it will b no different to the other joints on the bike, its always debatable if you strip the bike down that it will be problem free as a result, and save yourself 400 euros. Save the worlds resources:

 

[Pukmeister]

No chance of my frame cracking in the same place. Got the bike out the garage today, had a quick look, no bolt fitted.

Got a new bolt from Bahnstormers (M8x55 so quite long) and fitted with a little Loctite this time to 28Nm. The thread is quite deep inside the gearbox casing.

Totally transformed the way the bike feels, I can't believe the difference in ride comfort and handling that one small (and fairly insignificant looking) bolt can make.

 

[Bear]

They reckon it's a 5 hour job so should cost me about 440Euros, which I suppose isn't too bad......considering!


Opinions???

TTFN

Andy

I thought that my nearest dealer at GBP69/hour plus vat was a little overpriced. It's about the same as you've been quoted and I can't see what justifies it. If the frame breakage is down to a manufacturing fault then surely the labour should be provided as well as the part. I've worked on 30 year old Triumphs that lasted better than your GS.

 

[Pukmeister]

After riding my bike for a few days now since fitting the missing bolt to this 'failed' bracket, all I can say is get the cracked frame fixed or replaced ASAP, the difference is incredible.

Surely a local body shop could MIG weld the crack on your frame and apply some silver paint, it's in a pretty discrete area, if you hadn't mentioned it I wouldn't have thought to check and find a bolt missing so thanks very much.

The bike used to feel vague like it was tracking its own line, sort of like being hinged in the middle. That was obviously down to the fact that the frame/swingarm could flex sideways under cornering forces. Now that little bracket is secured to the engine/gearbox assembly, the bike feels so stable and sure footed when cornering and floats over bumps again.

If anyones bike feels unstable when cornering, check the small bracket and bolt are sound.

 

[Tomcat]

I had a close look at the bracket on my GS this weekend after reading this post - and it looks as though the bracket is fractured

It hasn't actually broken to the extent that there's a visible gap (as in the pics from Spain) but there is a fracture line visible in the paint, and can also be felt from below.

I had the clutch replaced recently so maybe the bolts weren't re-tightened in the correct sequence mentioned by vtwinmad.

Question now is how best to fix it? The bike is 04/54, well out of warranty. I'm inclined to get it welded, preferably in situ without dismantling the bike. Is there anyone here with welding experience who can say if this is feasible? If the battery is disconnected, is the CANBUS safe from being fried by the welding current? Also, any recommendations for a good welder in the Woking/Guildford area?

 

[WindyChuffer]

Surely welding is the cheapest, quickest and least intrusive option.

 

[Rich ZX12R]

Weld it but reserve right to change later if any doubt or recurrence.

Bin, Manufacturers warranty / goodwill doesn't work like that. Legally out of warranty means not really their problem. If they make an offer to do something outside the warranty terms then it is for now not some time in the future. Welding it now would make it even worse as when the part was returned (which they nearly all are to Germany) they would see the weld, say some-one has been "at it" and then reject it!

My advise take the new frame at four years old its a good offer!

 

[Tomcat]

OK, just had the offending bracket welded up - TIG on top, MIG underneath. No dismantling needed apart from removing the brake pedal micro switch, but the welder used a strip of alloy as a heat shield around the UJ gaiter. All seems fine now, and if anything the bike is a little smoother but that could be my imagination .

BTW, there are actually two brackets on the frame, both attached to the same bolt in the end of the gearbox. Only one of the brackets had fractured.

PS: anyone looking for a really helpful welder in the Aldershot area, call Ryan Holden at Ashby Welding and Fabrication on 01252 815811. Very helpful guy, happy to do small jobs on bikes and can weld alloy and Ti as well as steel etc.

 

[xz0skm]

OK, just had the offending bracket welded up - TIG on top, MIG underneath. No dismantling needed apart from removing the brake pedal micro switch, but the welder used a strip of alloy as a heat shield around the UJ gaiter. All seems fine now, and if anything the bike is a little smoother but that could be my imagination .

BTW, there are actually two brackets on the frame, both attached to the same bolt in the end of the gearbox. Only one of the brackets had fractured.

PS: anyone looking for a really helpful welder in the Aldershot area, call Ryan Holden at Ashby Welding and Fabrication on 01252 815811. Very helpful guy, happy to do small jobs on bikes and can weld alloy and Ti as well as steel etc.

I've nust found the same problem in my R1200GS, and I'me considering to weld it. How has performed your welded frame?.
How long you've been using your bike after welded?.

 

[gipsymagpie]

Snap!

Same has just happened on my 54 GS. Funnily enough, had a clutch replaced last year under warranty (oil leak) and it has just failed again. As they stripped the bike to check the clutch they noticed the fracture. Different garage this (North Ox BMW rather than Bahnstormers) so hopefully they will do it right this time. Thank god I bought an extended warranty again this year.