Headset Bracket Breaking

[Dejon Nell]

Hello gents

I have been experiencing breakage of the front bracket that is welded onto the headset tube (depicted in the photo with the yellow line). I had it welded but again on a long trip (offroad) the vibrations on the stutter bumps broke it again. Has anyone else experienced this problem? If so how did your remedy this from happening again? TIA for all your feedback.

 

[Squibb]

You have tried the only viable solution.

Have you got any extra weight on the cross bar, such as navs or phones? Many owners of Gen2 bikes have added bracing brackets between the screen adjusters & winglet mounting points to destress the front fairing.

The question is, did the weld fail, or has the bracket broken at a different point. Welding fractured alloy components is a dark art, a very specialist job, where unwanted heat transfer is the enemy. Tell us more.

 

[WJBertrand]

I believe this part of the frame is steel. Shouldn’t be too tricky to weld. The subframe however, is aluminum alloy.

 

[Dejon Nell]

You have tried the only viable solution.

Have you got any extra weight on the cross bar, such as navs or phones? Many owners of Gen2 bikes have added bracing brackets between the screen adjusters & winglet mounting points to destress the front fairing.

The question is, did the weld fail, or has the bracket broken at a different point. Welding fractured alloy components is a dark art, a very specialist job, where unwanted heat transfer is the enemy. Tell us more.

Hello,
Nothing mounted on the screen or any Nav bars etc. Stock Standard. The bracket broke mid center and not on the actual welding. Had it welded but broke again. Thinking of getting a plate added for more strength.

 

[Dejon Nell]

I believe this part of the frame is steel. Shouldn’t be too tricky to weld. The subframe however, is aluminum alloy.

Yeah, had it welded but again broke, going to re-enforce with a plate next time.