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San Antonio, TX, USA
Collective thoughts on fixing this? It’s chromo so I can tig it back together and possibly ad a chromo plate on the inside. I don’t know how long it’s been broken, I saw it when I was putting the engine back in after putting a new crank in it. Frame has 150 hours on it and I did swing arm bearings around 140 hours so sometime between then and now.
Popcorn out for this one.
How in the hell......
Guys who swear by flexy engine mounts can't believe you didn't feel that... lol
I like the idea of a plate on the backside. The airboot does sit sort of close there so you'll have to keep that in mind.
If it were mine I would trash it.
Not worth the gamble.
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That's an odd place for a break, no? Interesting for sure.
Is this one of those heat affected zone deals, being a little weaker from the initial welding in that area? Have to believe it would have fatigued long ago if so? Just more stress there as it's before a spar and close to where the engine mount maybe introduces some tension?
Looks quite strange at face value, but I don't know shit. I look forward to the educated comments (hell and the uneducated ones).
Know you'll get it stuck back together man, all the best with it 👍
Just drop the torque a few lbs and it's like riding on a cloud bro
No way I’d ever trust that.
This. I’d start fresh if it were mine (assuming new is available for you still). Curious - What year 250SX? Saw the exact same problem on a 2019-2022 TC250 frame recently as well…
Not worth a potentially lethal failure. Find a rolling frame and consider yourself very lucky
You can see where the boot already rubs on it. I can’t believe I didn’t feel it either, however my bike is really plush and soaks up bumps so maybe that’s why m I couldn’t feel the difference.
It’s a 2018. New frames are $1700 and I haven’t been able to locate a used one yet.
https://www.ebay.com/itm/176185823013?mkcid=16&mkevt=1&mkrid=711-127632…
First I’ve seen break in that spot. I know chromoly is supposed to be TIG welded and KTM is all mig. I don’t know if they post heat the frames before paint to relieve the stress or not. I would hope they would.
I saw that one, it was my understanding the husky sub frame and plastic mounts are in different locations tho.
That’s a hell of a break. I’d can it and start looking for something else, I’d say you got your monies worth.
That's how I feel, especially if the frame is still available new or with low hours.
On a trail bike, I might consider a weld with a diamond shaped plate there to spread the stress out.
A good-used frame for a late mode KTM is not that expensive and well worth the piece of mind.
RMATV...
2022 KTM 250SX
Frame 555S3 Part# 55503001000EB Our Price: $1,662.18
If that's too much, check MXLocker and eBay... Frames come up on those places all the time.
I have a 2002 YZ250 frame that cracked across the front down tube just above Y for the cradle. That bike had hundreds of hours of hard moto. I grabbed a good 2003 frame even though I have all the production welding equipment to fix it.
KX500 frames crack up by the shock tower through one of the longer welds. I've repaired that crack on a buddy's frame and done some welding to replace foot peg mounts with upgrade parts and consider those bikes 100% safe.
Try CM off road in AZ. They part out a ton of bikes.
Frame is Backordered with no ETA from KTM. Good Luck.
Sexton's frame probably looks like that now
Pit Row
I'm the odd man out here, I'm going with tig it and an overlay plate. Do regular inspections. I can't imagine a catastrophic failure doing that. He's been riding it completely broken like this and didn't even notice it and doesn't even know how long it's been like that. It also really depends on how you ride too though.
Tank mount is the same for KTM/Husq/GasGas. I’m nearly 100% positive all the subframes mount the same on all three bikes.
You’re probably right, but I personally wouldn’t be able to ride it without getting that thought out of my head. If I was an engineer and understood Yield, flex, etc then maybe it’d be different, but I’d much prefer picking up something that’s still in one piece. Just my $0.02.
If you spend $60 (I think?) on a KTM Talk membership, Munn racing gives some pretty good discounts:
I tell my son sometimes that you guys have it pretty damn good. Things are so reliable these days. It's pretty rare that when you go out riding and something breaks and your day is cut short. I mostly JetSki'd and we just expected we'd be towing someone home. But back to the topic on hand, back in the 70s I don't think you could find a bike that didn't have the frame welded up some how, some where. In todays age we think of it as dangerous, and it is a risk, but in previous days, it was just expected at some point you'd be welding on the frame somewhere. In this case, if someone does not have confidence in their equipment, it was the wrong decision.
TM
Weld and plate it . It will be 100% . check it after every ride .
Weld it and send it. How do you think they are put together anyway?
This is the direction I’ve been leaning. We have some 1/8” chromoly plate at the shop that I can fab a back plate out of. Actually I think I can get two strips on the back and front of that inside section. I send it off big jumps and it hasn’t catastrophically ended my day yet.
... a take on other memes I've seen where people wear through the subframe with their boots.....
I know they were likely lower consistency blends or varying quality control, assembly or treatment processes (although I swear chromoly has been around since world war II at least), but I was gonna say I'm sure those old timer heros who were hauling ass with sporks as footpegs and barely knobby tyres were welding frames up every other week and proceeding to send it 😂
Granted new frames probably weren't as readily available and they weren't airing the thing out like AJ does... But if it didn't let go while it was like that and you have the facilities and skills to try a repair, I'd give it a go. I'm a cheap bastard though.
If you do that - Do the same to the other side - the tube over tube reinforcement.
Because if one side has broken, the other side is on the way to do so, as well.
And, strip the entire frame of paint, and check Every section of it.
I do a fair few frame repairs, and, I'm yet to have to do one like that - though, It certainly is a high stress tube section with regards to that area of the KTM frame - well, All frames.
But such severe damage, really makes me think a new, or very lightly used frame might be the safest way forward.
When you say your bike is Plush, have you been severely bottoming it through that plushness? I've a mate that Always sets up his bikes that way, whilst being blazingly fast, with little mechanical sympathy. Works for Him, but he does damage Frames, Swingarms, Shocks and wheels, quite often, and in Quite Unique ways. And I'm the mug that fixes it all.........
Just out of curiosity. Can you tell us what led to this point?
What kind of riding?
How many hours?
Speed level?
Stuff like that
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