FRAME CRACKED!! Please Help

[Shonto rider]

Anyone else that had there frame crack right here, on a 2003 400ex. It looks like a clean crack. Im thinking of welding it, but I don't know what amprage to use on it. Do I use an ARC WELDER. Please help me. HOW CAN I FIX IT> HELP ME!

[MadMax27]

Make a sleeve or fit up a slug, leave 3/16" spacing if you use a slug, then you can do 2 butt-welds this will ensure a strong joint. Use a Mig or Tig. An Arc is an excellent, strong weld, but for tubing its a little overpowering. If you are accomplished at ARC then go for it. I wouldnt. While your at it, gusset your frame to make it solid. I have had great luck on my 400's frame with my Glue Gun, set the amps low to start and a medium speed wire feed.

[Shonto rider]

What do yuo mean by gusset the frame?:ermm:

[bonified5]

it means to buy little metal pieces that they sell and you weld them to the frames joints and angles to make it stronger.

[44oEX]

put guessets in the weak spots, bracess, reinforce it.

And if you don't know what kind of welder to use and at what power I would say get it done by a pro for like 50$, it will be a way better job

bring it to a wielding shop! they will do it up right.

Just make shure that you tear the bike doun far enough for them to have room to work on the crack. I could weld it so you wouldent be able to tell there was a crack. but the best way as staited before is to put a pice of pipe over the existing frame.

[6858-400ex]

that is exactly were mine broke because of the motor mount on top did not have enough spacers so i added a few washers and it lined right back up i used a tig welder:mad: :confused:

[ss440ex]

Gussetts!!!
How is gussetting your frame going to help it in that area????
Weld it back together,
Grind it smooth,
do a single finger wrap repair 1 inch pass the damaged area
on both sides.

[DeerNuts]

Originally posted by ss440ex
Gussetts!!!
How is gussetting your frame going to help it in that area????
\

Well it wont really. That's not what they meant. They meant, "While your at it (welding) you might as well gusset your frame also.;)

[prepracing]

hey there MadMAx, just wondering how the hec you would put a sleeve inside the frame there ????