Long ago when I installed the Edge taillight kit and Maier 300 rear fender, I had to do some modifications to the tail end of the bikes frame. This was a common practice with the mods that I was doing and the only way to get the fender to fit. Because I was young and stupid, I used JB weld to try to reinforce the frame.

Now the JB Weld has failed and the tail piece of the rear frame is lacking structural integrity. I would like to get this fixed, and would like advice on the best way to do so. I'm assuming that a moderately competent welder could patch it up, but I don't know since it's so close to everything else (wiring, air box, etc). I've never had anything welded before.

What do you guys think is the best way to fix this?

Thanks!

 

Looks like you will have to cut everything off, square up the cut ends, find a piece of bar stock that fits the ID of the tubing, then have it welded up. think exactly that has been done before and documented here on KF.
Dan

 

Easy job for somebody with a little experience.

 

I've seen a couple fixed and/or reinforced with Dan's recommendation here.

Disconnect battery and remove the ECU before welding.

 

^^^ This for sure... thin wall, heat range important, but easy enough.

How did that happen? Wheelie gone wrong?

 

No luck so far finding that thread. Do you happen to remember the users name or the context of the thread so I can do some better searches? Thanks

 

That looks bad.
1. take everything off.
2. measure the ID of both tubes, see if they are straight in-line or whether it turns at the junction.
3. order the steel tubing to go inside the frame tubes at least 3-4" (it may not go all the way, but you want to go as far as you can to about that depth. Sand all connections and get the tubes you ordered to stick into the bike frame.
4. pull the tube out and drill about 4 1/8" dia holes in the frame at various locations that would expose the new tubing.
5. Take it to a professional welder and tell him to get'er done.
6. I purchased a 1"x1"x 14" long steel angle and also had him put it on from down below the battery on the bottom to out as far as you can on the tail section to help brace it on the battery side. (the muffler is in the way on the other side)
Put everything back.
I think the welder would use a acetelene torch, not an elec but if he uses elec. take the battery off line and tape all positive loose wires.

 

https://www.kawasakiforums.com/forum...e-42264/page2/

You should bend all those parts back together and put an additional plate on them and have the welder make those heavier.

 

Sorry cant remember who it was. Thread durielk posted is one but i seem to remember another one more involved. Search feature here on KF is weak, that's one reason i try to be very specific when naming threads i start ( so people can find them using the search) I will try to look around and find the thread.
Dan

 

I plugged "subframe" into the search box and skimmed through 6 pages of results. Saw a few threads about broken subframes but many had dead picture links. Heres one with some info.
https://www.kawasakiforums.com/forum...ubframe-30930/
Im sure there are other threads with info in them , but some of the titles dont give a clue to what the thread is about. ... Something like "OMG! look what happened today" doesn't give you a clue.