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Old 05-31-2004, 11:33 PM   #1
scottw OP
Steppe Rider
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Joined: Sep 2002
Location: Tokyo
Oddometer: 291
Eh? Broken R100GS subframe

Well, took off the seat today to get at the toolkit and found a clean snap in the right rear subframe. Must have happened last weekend when I went offroading for about 50 hard miles. Will have to get it to a welding shop later this week.

As long as I'm taking it to a welder, any suggestions for how to fix and strengthen it for the future? I'm going to have them beef up the left side as well while they're at it. I guess these things happen when you're trying to make it act like a 500 pound dirt bike.

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Old 06-01-2004, 02:21 AM   #2
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Location: Townsville ,Queensland, Australia
Oddometer: 1,326

I think BMW has a mod out for problem, I seem to remember it was for Aust and Canada.

Good Luck.
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Old 06-01-2004, 05:39 AM   #3
Rubber Cow
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Location: Aloha... yes, Aloha, Oregon
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There is a freame gussetting kit available from HPN/Wudo and I think Touratech as well. It is only intended to reenforce the main frame. Unfortunatly, this has the effect of stiffening the frame too much and causing it to crack in other in the middle of the top tube. Not good.
The best thing to do with the subframe is to have an identical one made up out of better, higher grade chromoly tubing. High end bicycle tubing would work in a pinch.
Jim Rowley of MAP Engineering or HPN may be able to sell you or at least suggest some alternative/stronger designs.
My suggestion would be to remove the subframe, cut it in the identical spot on the left side, insert a tube/hollow pin between the broken bits, braze it in place or at least cross pin it, and then weld the subframe back together.

What were you doing and how much load was on the seat and rack?

Hope this helps.
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Old 06-01-2004, 05:24 PM   #4
scottw OP
Steppe Rider
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Joined: Sep 2002
Location: Tokyo
Oddometer: 291
Thanks for the suggestions Jorge. I don't know exactly when it happened, but there was no extra weight on the rack or rear part of the seat. Of course, I weigh 260 (probably 280 in full ATGATT) so that's not insubstantial. But my weight is usually more forward.

I'll try MAP Engineering and HPN. I have the HPN tank on the bike. Good stuff, but expensive.

About 90% of my riding is off-road, on dirt tracks or cross-country. It's not like I'm doing jumps or anything, but many hours of very bad dirt roads or bumpy pasture land at 25-50 MPH, so a lot of rattling and hits.

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Old 06-01-2004, 05:36 PM   #5
Frank Warner
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Joined: Mar 2002
Location: Sydney, Australia
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HPN reinforce that part of the frame buy adding another frame tube - to form a larger tiangled section towards the rear of the bike,

Runs from the rear part of the rear rack towards the bottom frame attachment point - near the swing arm pivot point.

This will not cause other parts of the frame to brake earlier than they other wise would.

--- From the photo - the frame gusset has been broken for some time - rusty. The frame tube is recent - no rust. Perhaps others can use this as a test for frame failure?
Regards Frank Warner
motorcycles BMW R80 G/S 1981, BMW K11LT 1993, BMW K75 G/S

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Old 06-02-2004, 06:35 AM   #6
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Joined: Sep 2003
Location: Nazareth, PA
Oddometer: 277
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Subframe broke on my 95 RS two weeks ago. ~$450 for an updated subframe and ~$80 for the updated luggage assembly. I figured I would do all the maintanence now, clutch, splines, rear main seal. I had the biked stripped and trans out in two hours.
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95 R1100RSL
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