Ugh! Really bad news. I discovered my frame is cracked!

[Ack535]

So I was working on my bike today, and couldn't figure out why something wasn't lining up the way it should.

Pulled the footpeg bracket away and discovered this!





At the top of the crack there is about a 1-2mm gap.

Needless to say, I am a bit sick to my stomach, and I am really pissed...

Anyone aware of this being a problem and/or recall? I googled the issue, and not much came up. As always, any thoughts or input is appreciated. I may just end up parting the bike out.

[ddlewis]

Yikes!

In all my years on FJ lists I don't recall any spontaneous frame cracking.  What's the history on this bike, any accidents?  wonder if it was ever bent/straightened?

[1tinindian]

1- Part it out
2- Weld it up

I vote for #2

Leon

[rktmanfj]

 

That pic prompted me to go out and check the frame on my '89, since it has had a couple of unintended flights.

Nothing broken other than the two broken frame cradle bolts (repairs were already underway).

[mz_rider]

Pete,

This happened to the older of my two FJs. I think it was caused by the bolts connecting the lower frame loop to the main frame (at the footrest) shearing and causing stress in the frame. I did a repair by MIG welding without removing the motor etc and this has held. But yours looks worse - a wider crack and it is probably all the way round. I think your options are a strip down & have it repaired by a competent welder or look for another frame. 

Stuart (Glasgow, Scotland)

[movenon]

Well the good news is you found it and it is repairable. I think you can remove the rear sub frame and airbox, AL. side casting, protect the wiring etc. and weld it. If it were me I would look into "fish plating" it on the back side. It looks a bit tight but doable.

That point see's all the stress from the upper rear shock cross mount and foot pegs. Check both sides. Also I would do a good inspection of the swing arm bearings, relay arm and lower shock assembly very closely. Some force caused that to break.

I have never heard of a factory recall related to your problem but there are a lot of members here with more historical experience with the FJ's than me.
I see that the break is right next to a factory weld so possably there was some weakness in the metal in that area do to molecular changes in the metal. But all that isn't going to change anything...  A good inspection point add to the check list. Just went out an checked mine..... No problem found.

Its a bummer but like I said the good news is you found it and it can be fixed.

George

[Ack535]

Thanks for the input guys. I must admit I am very hesitant to weld the frame for fear of it breaking again. It's a safety issue.

As much as I hate to, I am going to have to part her out. I would not want to get hurt, or have someone else get hurt over a cracked frame. Not worth it...

[movenon]

What parts you got?  I wouldn't hesitate to fix it. What are you going to do this winter anyhow ?    

George

[racerrad8]

How about the other side, any signs of cracking there?

Randy - RPM

[aviationfred]

Before you part it out, maybe put the bike up for sale. There may be someone on the forum that would like to have the whole bike.

Fred

[Capn Ron]

Wow...this is discouraging!  I'm sure your heart sank when you discovered that.

Everyone's situation is different and I'm sure you'll figure out the best move for you...It seems like you do have several options though.

* Reweld in place
* Reweld with "fisheyed" backing plate(s)
* Part out the bike (I, for one would be first in line for parts as I have the same '92 ABS)
* Sell the bike as-is with the known frame crack (There might be enough "spares" on it to make it worth it for someone here)
* Replace the frame.  There's one from a '91 on Ebay that looks near perfect:

http://www.ebay.com/itm/YAMAHA-FJ1200-FJ-1200-1991-91-FRAME-RAIL-VERY-NICE-6-5-K-MILES-EZ-REG-/370820895940?pt=Motorcycles_Parts_Accessories&hash=item5656a5d4c4&vxp=mtr#ht_6242wt_924


That's pretty involved doing a complete tear-down, but if done with a "rebuild" mindset, you'd end up with a very solid/fresh bike!

Cap'n Ron. . .

[Ack535]

I spent the afternoon carefully disassembling the bike as I am going to part it out. I just can't sell a whole bike with a cracked frame as badly as this one is. Someone could get hurt or killed riding this bike...

Look for my post later today on the fire sale of used parts for the 1992 FJ1200ABS.

[aviationfred]

Wow...this is discouraging!  I'm sure your heart sank when you discovered that.

Everyone's situation is different and I'm sure you'll figure out the best move for you...It seems like you do have several options though.

* Reweld in place
* Reweld with "fisheyed" backing plate(s)
* Part out the bike (I, for one would be first in line for parts as I have the same '92 ABS)
* Sell the bike as-is with the known frame crack (There might be enough "spares" on it to make it worth it for someone here)
* Replace the frame.  There's one from a '91 on Ebay that looks near perfect:

http://www.ebay.com/itm/YAMAHA-FJ1200-FJ-1200-1991-91-FRAME-RAIL-VERY-NICE-6-5-K-MILES-EZ-REG-/370820895940?pt=Motorcycles_Parts_Accessories&hash=item5656a5d4c4&vxp=mtr#ht_6242wt_924


That's pretty involved doing a complete tear-down, but if done with a "rebuild" mindset, you'd end up with a very solid/fresh bike!

Cap'n Ron. . .

++1 

[Ack535]

I had a friend of mine who is an automotive engineer for Ford take a look at the bike. He agreed a weld fix may work, but it would be a complete tear down to get the fram straight to weld it. I am just not comfortable either riding and/or selling a bike that had such a serious defect.

Looking at it closely the weld failed in the backside of the frame.

Watch for parts coming soon in the parts for sale section!

[ribbert]

No big deal, a bit of shielding and weld up in-situ. I know it's a shock because it's a major component but don't forget, the rest of the bike is held together with welds. If not confident in your own welding get someone to do it, won't take long.

Here's mine, 75,000 hard km's later, no problem.



It has been welded all the way around on both sides.
I have a spare frame and changing them here has no registration issues, but why bother. I check the welds from time to time and it's fine.
Fix it! Any other solution is going to throw away a lot of money and leave you FJless.

It would be a crime to part out such a magnificent piece of machinery over a simple crack.

FJ#2 has a rusty line where the paint has come off consistent with flexing in the exact same spot. That bike came to me with 3 of the 4 lower subframe rail bolts missing, sheared or stripped. Never given it much thought but I did wonder if this could transfer load to that part of the frame. Something for the thinkers here to mull over.


Noel