I learned a few things tonight, I'm keeping the 950, sending suspension to SPS, getting Safari tanks and buying a Sat phone. Excellent fix btw both on and off the trail!!
I like how you handled the situation, You must love this bike so much! anyone else would have made a big fuss about it and would never ride a KTM again but I see you have fixed it and riding it again.
For all of you who think it was my payload that caused the failure...ktm specs claim max payload @ 205kg (452lbs.) I weigh with gear around 225lbs. Leaving 227lbs. On the table. Also to much weight on the rack would cause the subframe to break not the main frame. After reviewing my photos from earlier that day I could see that the frame was broke many miles before and what I heard snap was actually the subframe finally giving in to the stress of holding the whole bike together. I have since put another 6000 hard miles on it since my fix and haven't even bent the upper shock bolt (the 2014 model is notorious for this). I also really like how rigid it made my rear end much more stable on road and off!
I think the same as you, the crack was in a central zone, not in the tail one. Also, the bike should be able to carry a passenger of 75-80 Kg without problems. That's an evident problem of poor material quality, since the weldings seems ok. I would substitute the entire frame, I think it cannot be trusted anymore.
Nice job on the frame gusset to add rigidity. Can't help but think of Ewan and Charlie in Mongolia on LWR with a frame failure, too. Surely they were carrying more gear than you. You fellows handled the circumstances with aplomb to get you back to where you could repair it. Well-done!
Remarkable the way you did the repair on the trail and then in the workshop. If we are going to drive anywhere, we must be prepared for those surprises.
Holy fuxxing shxt! 😳😳😳 Amazing work their guys both keeping it together when it happen and the way it has been fixed. Would like to hear a word from ktm on this though....
Definitely look at tour manual for max load weights and understand that you have to into account more rough terrain. As it increases the stress load on all the parts of the bike.
Nice fix , certainly not going to break again. Good to see some old fashioned common sense in action, something that seems lacking in many adventure vids
I would suggest lighter loads. I would have bought a new KTM or better yet a Husky 701 E and parted out the old girl. I bet you will have cracks agin because of all the heat zones caused by welding. The frame has to flex or it will crack. My son and his friend just rode the TAT on new Husky 701 Es with no issues. The polymer rear frame tank setup allows for flex so no frame cracks. They were also very careful about weight. They packed like a mountain climber would. Grams = pounds = cracks in the support structures... Pleased to see you folks made it out of the bush ok.
At the beginning I was thinking the same as you, but maybe that was not the problem. The bike should be robust enough to hold a passenger of 75-80 kg. Also the crack was located in a central zone, not in the tail zone...
Yeah may be the crack is on front but that kind of frames supports each other to hold together. So the over pressure on back may end up with very high tension on front.
Nice work Tyler! That is some serious frame failure and good trail ingenuity. The welding job looks great and looks like an improvement over stock. Glad the straps got you home. Cheers, Tibby
Looking like some thin thin wall chromemoly tubing.emphasis on thin.going to rethink a ktm purchase decision.BMW and triumph just moved up in consideration as well as yamaha
By my reckoning you’re almost at double the specified limit. If I’ve made an error let me know as I’m more familiar with metric, but I believe these figures are close. 2 x 2 gallon gas pax weigh 7.6 lbs empty, plus the 3.6 lbs for empty water pax makes 11.2 lbs. 2 US gallons of gasoline weighs around 12.4lbs, so with the empty pax we’re now at 23.6 lbs. Apparently you sometimes had 1 gallon of water, weighing 8.3 pounds. We’re now up to 31.9 pounds, excluding tubes and mounting fixtures. That’s almost double the engineered weight limit. All that weight is carried right at the very end of the subframe, so the leverage on the front portion of the subframe where it attaches to the trellis frame is substantial. Personally I think an Adventure bike should be engineered to carry more than 18 lbs on the rear rack, but as it’s not I think running over 32 lbs off road is probably where the problem started.
A shot of what actually happened with getting it back. Did you ratchet strap it and ride it out? Or did you get pulled out? I thought I heard the one guy say that.
I wonder what a KTM engineer would think of this fix? I’m not a metal fab guy but I wonder if tube frames like that are designed to flex, and wether this might make it to rigid in that area and cause an overload in another area?
I’m a mechanical engineer, it will likely transfer the stress to another location creating the next weak spot. However it will be better than before since it would be likely the 2nd or 3rd weakest spot on the original frame. Overall won’t be a whole lot stronger than before but certainly won’t break in the same place. Probably changes handling a good but but unlikely he will even notice
It's an old story already but sorry to hear that. I have a 1190 too and some friends have them, we never had any issues. Maybe with all weight on you hit hard or had really bad luck. Fixed it well, safe ride!
On the 2015 model ktm bridge the top shock mount to reduce flex so you'll probably ok but I'd still put the powercell 12.9 bolts in place of the stock 10.9's.
Wow, that is definitely a break! I see the bike is not standard paint... had it been crashed on the road previously? I wonder if it was cracked long before the trip?
SPS has zero fault in this! f.y.i that's me and my bike...and come to find out after doing some research after this incident it was a design flaw where KTM didn't support the upper shock mount properly which allows flex and was bending bolts. I just happened to have bent the bolt to the point the frame broke which in turn eventually broke the subframe. KTM addressed the issues in the 2015 frame by bridging the upper shock mount. SPS did my suspension on my 950 also with no issues...they are the best when it comes to tuning suspension
I would argue that the SPS helped make it last longer than the original suspension would have. Better small bump compliance and less bottoming greatly reduces the load that is transferred to the frame. LOVE my SPS.
Great attitude !! I suppose we should all learn from this mans issues . I will surely look at my 1190r & possibly do some gussets on the rear & subframe .
How can you not subscribe after this video..great attitude and problem solving skills..love the fix..I've been really concerned about my 16' 690R with no subframe..I want to reinforce the existing frame somewhat like KTM did with their factory rally..because I'm a big guy and with no subframe and too much luggage sometimes riding alone..GREAT ATTITUDE AND FIX!
How the hell could this broke?! I am completely new to KTM and recently bought a brand new 1090 R. Wondering if this could happen too... So far I've trusted the guys from Austria of course. Btw, good job for your improvisation and fix.
Not sure how that would have happened but have got one of these so it worries me. Already had a problem with mine but have posted a solution video which is no where near as bad as this!!
The failure was uniform, so from the engineering standpoint, it would probably equate to being overweight or close to max with increased downward force while off-road. Further, when you are riding the rear did not appear to use the rear shock or travel down and rebound. Offroad settings usually mean you set rebound high, so this tells me the rear spring sucks, was not set properly, or is not rated for that weight. Glad you fixed though, I love my KTMs and have never had an issue offroad on heavily loaded bikes on the same BDR routes you were on. I know you know all of this, just trying to think of a way a uniform frame break would occur, I don’t think a a few isolated event is a design flaw, perhaps quality control issues though. Ride safe.
Nah, I've got a '14 1190R with 30k miles on it and it's a beefy as heck frame. If I had to guess the suspension on it got bottomed out pretty dang hard to crack it, and then riding it fully loaded for miles and miles (without noticing the crack) until it failed in other places.
Jacob Alheid Even if this is true it the frame shouldn’t crack. It’s chrome molly. The dealer should support you and get support form the manufacturer. Wrote to them. You should not be riding with a welded frame and the weld may crack again. Cheers.
If you look at where the weight is slung it is too far back and definately caused the failure. I agree it should be stronger but it's not. Well, now it is. Great fix.
My KTM is only a 300exc, but I've had some fundamental floors that I really wasn't expecting from the brand. So has my boy's 65cc...with an issue that should never have left the factory!! I still love the brand.. no one is perfect....
There just no way that could every happen to an unbreakable, awesome, perfect KTM. (sarcasm) Great final fix though. Maybe KTM should hire you as an engineer? 50,000 miles on my KLR...not one issue, other than it's a KLR.
Did he even jump that bike how in the hell does a frame break like that ... I crash my wr 250f at almost 90 kms per hour and snapped my leg .... no damage to bike and now leg is better then ever
But your enduro bike weight 110kg... And is not loaded with ton of camping gear. That's the problem : contstant stress on the frame. But it's no excuse, at this sell price, you MUST NOT BE WORRIED ABOUT THE RESISTANCE OF THE FRAME. For me, the best thing is to contact KTM and work with them to solve this problem
Was getting ready to trade in my Ninja 1000 for KTM Super Duke today but after watching this I think I better look to Yamaha MT-10...so thanks for opening my eyes
The main frame of my 2014 1190 Adventure-R with 24,000k's on it broke in exactly the same places as yours did. I was 7 days into a back country trip in the South Island of New Zealand at the time but I travel light (one 30L bag) and I weigh 81kg so I agree with your comments that your frame breaking isn't down to your bike being overloaded. I was riding along Skippers Canyon Road (www.dangerousroads.org/australia-and-oceania/new-zealand/55-skippers-canyon-road-new-zealand.html) when I noticed something wrong... I'm glad I wasn't doing any serious power slides at the time! I went the new frame route but I like the look of your rebuild and the gussets that you've put in, nice work.
This frame failure issue has me worried. Was your 30L bag strapped on the tail rack or on the pillion seat? Did you do any hard off road riding / jumps before the failure?
The bag was strapped across the pillion seat. It probably only weighed 10kg max. I was riding it like it's meant to be ridden (hard off road, across rivers etc.) but not doing jumps as such. I've ridden dirt bikes since I was 10 (I'm 49 now) and this is the first bike I've ever had snap in half on me. It's not a great look for a bike that is marketed to be ridden hard and personally I don't think it should have broken. Having said that at the end of the day sometimes shit happens. Anyone who has watched The Long Way Around has seen how many times the BMW's broke on that trip - I'm not picking on those bikes but it highlights that that's the way it goes sometimes when machinery is being pushed. I still love my 1190, when I'm not riding my 300 EXC I can take my wife out for a skid on the gravel roads, which she loves, and earn brownie points while having a great ride - that's pretty damn hard to beat :-)
I would think KTM would be interested in your solution--it look like what should have been done by KTM when they built the bike! Outstanding solution and a fix to a known problem--uh.....KTM? You listening???
I'm a welder by trade and I can it,but to tear down the bike and put back together not even in my dreams. To pay someone to do that's a hefty bill. Hopefully that doesn't happen to my 2017 1090R.
KTMs are notorious for bad quality. They are the equivalent of Alfa Romeos - built to be the best but only for a short while. They win the Dakar year after year but you won't find many going around the globe.
That is very odd! These are bikes that have won the Dakar 16 - 17 years in a row! I think what went wrong is that buddy had way too much weight on the back, but also he had all that weight at the furthest point on the bike and with the ruff terrain, it broke.
I learned a few things tonight, I'm keeping the 950, sending suspension to SPS, getting Safari tanks and buying a Sat phone. Excellent fix btw both on and off the trail!!
I like how you handled the situation, You must love this bike so much! anyone else would have made a big fuss about it and would never ride a KTM again but I see you have fixed it and riding it again.
For all of you who think it was my payload that caused the failure...ktm specs claim max payload @ 205kg (452lbs.) I weigh with gear around 225lbs. Leaving 227lbs. On the table. Also to much weight on the rack would cause the subframe to break not the main frame. After reviewing my photos from earlier that day I could see that the frame was broke many miles before and what I heard snap was actually the subframe finally giving in to the stress of holding the whole bike together. I have since put another 6000 hard miles on it since my fix and haven't even bent the upper shock bolt (the 2014 model is notorious for this). I also really like how rigid it made my rear end much more stable on road and off!
I think the same as you, the crack was in a central zone, not in the tail one. Also, the bike should be able to carry a passenger of 75-80 Kg without problems.
That's an evident problem of poor material quality, since the weldings seems ok. I would substitute the entire frame, I think it cannot be trusted anymore.
For sure, that gusset should have been a factory piece, I swear though the last 690 frame I saw was a thicker wall tube....quite odd!
Nice job on the frame gusset to add rigidity. Can't help but think of Ewan and Charlie in Mongolia on LWR with a frame failure, too. Surely they were carrying more gear than you. You fellows handled the circumstances with aplomb to get you back to where you could repair it. Well-done!
Tyler like how you guys McGyved the repairs. Something to show my friends
Tyler ... That my friend is the correct attitude ...and great on rd fix to get her home ..kudos to you both
I giggled when you said "now we're gonna load everything on my bike". 990 saving the day! :)
Remarkable the way you did the repair on the trail and then in the workshop. If we are going to drive anywhere, we must be prepared for those surprises.
Strong work, man! I'm shocked you don't have more subs. As an aside, the guys at SPS did the suspension on my 5th-gen VFR and did a great job.
All I can say, well done gentleman. Thumbs up from the Czech republis.
Holy fuxxing shxt! 😳😳😳 Amazing work their guys both keeping it together when it happen and the way it has been fixed. Would like to hear a word from ktm on this though....
LOVE the channel! Your videos are pure quality. Amazing fix guys. Looking forward to your next videos!
and what does KTM officials say about it ?
I wanna know too
this could be a very expensive potentional factory recall. i am looking into buying 1090... are those with the same frame?
good question ...
doncarlo5 having just seen that I wouldn’t go near one let alone buy one , I think the shower riser in my bathroom is a thicker gauge tube than that!
ah ah .... not bad ( german word for bathroom ) : )
Well handled.. Was the Frame not covered by warranty ? Even when the warranty was over i would knock on Ktms Door for a new Frame
Georg Rettenbacher There's just a big fuss with the registration if the frame is swapped and you have to change the plates for the new frame
Great job with restoring the frame!
Definitely look at tour manual for max load weights and understand that you have to into account more rough terrain. As it increases the stress load on all the parts of the bike.
Was or is that a first year model issue? Frame looks unchanged compared to my 2015 r. Now I should go check.....
Nice fix , certainly not going to break again. Good to see some old fashioned common sense in action, something that seems lacking in many adventure vids
Thank you for a intelligent comment! Not many these days... CHEERS
I would suggest lighter loads. I would have bought a new KTM or better yet a Husky 701 E and parted out the old girl. I bet you will have cracks agin because of all the heat zones caused by welding. The frame has to flex or it will crack.
My son and his friend just rode the TAT on new Husky 701 Es with no issues. The polymer rear frame tank setup allows for flex so no frame cracks. They were also very careful about weight. They packed like a mountain climber would. Grams = pounds = cracks in the support structures...
Pleased to see you folks made it out of the bush ok.
Being a new 1190R owner I was scared to watch. Now seeing all those damn cans on the back. Im feeling better.
Probably a good idea for us all to give ours a check. I’m assuming there wasn’t a change on the manufacturing with year changes?
only one question - how much luggage did you have?
At the beginning I was thinking the same as you, but maybe that was not the problem. The bike should be robust enough to hold a passenger of 75-80 kg. Also the crack was located in a central zone, not in the tail zone...
Yeah may be the crack is on front but that kind of frames supports each other to hold together. So the over pressure on back may end up with very high tension on front.
Nice work Tyler! That is some serious frame failure and good trail ingenuity. The welding job looks great and looks like an improvement over stock. Glad the straps got you home.
Cheers,
Tibby
So, any thoughts on the cause of this failure?
Looking like some thin thin wall chromemoly tubing.emphasis on thin.going to rethink a ktm purchase decision.BMW and triumph just moved up in consideration as well as yamaha
By my reckoning you’re almost at double the specified limit. If I’ve made an error let me know as I’m more familiar with metric, but I believe these figures are close.
2 x 2 gallon gas pax weigh 7.6 lbs empty, plus the 3.6 lbs for empty water pax makes 11.2 lbs.
2 US gallons of gasoline weighs around 12.4lbs, so with the empty pax we’re now at 23.6 lbs.
Apparently you sometimes had 1 gallon of water, weighing 8.3 pounds.
We’re now up to 31.9 pounds, excluding tubes and mounting fixtures.
That’s almost double the engineered weight limit.
All that weight is carried right at the very end of the subframe, so the leverage on the front portion of the subframe where it attaches to the trellis frame is substantial.
Personally I think an Adventure bike should be engineered to carry more than 18 lbs on the rear rack, but as it’s not I think running over 32 lbs off road is probably where the problem started.
whats another bike more better besides ktm because from watching this i dont think i want to buy one now any suggestion???
Superb repair job too. that reinforced frame looks great.
Did you overload the bike on rough terrain or something?
A shot of what actually happened with getting it back. Did you ratchet strap it and ride it out? Or did you get pulled out? I thought I heard the one guy say that.
This is not ok regardless of weight. I'm getting a 1290 finally and I think the crack issues have been fixed.
I wonder what a KTM engineer would think of this fix? I’m not a metal fab guy but I wonder if tube frames like that are designed to flex, and wether this might make it to rigid in that area and cause an overload in another area?
I’m a mechanical engineer, it will likely transfer the stress to another location creating the next weak spot. However it will be better than before since it would be likely the 2nd or 3rd weakest spot on the original frame. Overall won’t be a whole lot stronger than before but certainly won’t break in the same place. Probably changes handling a good but but unlikely he will even notice
It's an old story already but sorry to hear that. I have a 1190 too and some friends have them, we never had any issues. Maybe with all weight on you hit hard or had really bad luck. Fixed it well, safe ride!
I heard the 2021 adventure 1290's frames will be made of aircraft aluminum to make the bike weigh less, will this be stronger or weaker?
Is this problem on all Ktm advantures?
My buddy's 1190 frame just cracked this past weekend at our Mojave event
It is a serious problem for sure I hear about it happening too often.
Buildyear?
@@Flip2theOzz 2014
This happens only in the bikes in the off-road or happens the same to the ktm 1190 that only ride in the street/road?
@@pedras17 I would guess off road in most all the cases.
Have you contacted KTM?
Nice job getting it out of the backcountry. Looks like you must have bottomed the shock really hard to get that to break.
How did that happen?
How is the repair holding up? Mine has broken nearly in the same places.
I've put 10,000 hard miles on it and haven't had any more issues with it!
I'm going to look at a used 2015 1190 adventure . I'm thinking maybe I should just cancel now and look for something else?
On the 2015 model ktm bridge the top shock mount to reduce flex so you'll probably ok but I'd still put the powercell 12.9 bolts in place of the stock 10.9's.
New 1290r is a hard core weapon
Go for the KTM it's a great bike ..
Wow, that is definitely a break! I see the bike is not standard paint... had it been crashed on the road previously? I wonder if it was cracked long before the trip?
I did a vehicle wrap on it to make it different.
Don’t forget you can carry luggage on the front crash bars to evenly distribute weight if you are carrying a lot of cargo.
Did you guys send thus to ktm to show them they need to build better frames. Thin ass tubing.
So might be a good idea to have those supports welded in when bought as new and going off on a long ride. good to know.
Shouldn't that we under warranty?
I wish KTM would address all of their factory flaws not just the egregious ones like this.
I see you have super plush suspension. Is it possible that may have aided in this? Only curious as I plan on getting a suspension upgrade too.
SPS has zero fault in this! f.y.i that's me and my bike...and come to find out after doing some research after this incident it was a design flaw where KTM didn't support the upper shock mount properly which allows flex and was bending bolts. I just happened to have bent the bolt to the point the frame broke which in turn eventually broke the subframe. KTM addressed the issues in the 2015 frame by bridging the upper shock mount. SPS did my suspension on my 950 also with no issues...they are the best when it comes to tuning suspension
I would not ride an adventure bike without Super Plush Suspension!!!!! Every bike I ride or ride with has been worked over by SPS. Game changer.
I would argue that the SPS helped make it last longer than the original suspension would have. Better small bump compliance and less bottoming greatly reduces the load that is transferred to the frame. LOVE my SPS.
Great attitude !! I suppose we should all learn from this mans issues . I will surely look at my 1190r & possibly do some gussets on the rear & subframe .
How can you not subscribe after this video..great attitude and problem solving skills..love the fix..I've been really concerned about my 16' 690R with no subframe..I want to reinforce the existing frame somewhat like KTM did with their factory rally..because I'm a big guy and with no subframe and too much luggage sometimes riding alone..GREAT ATTITUDE AND FIX!
So was there any reason for the break? did you bottom out on some jumps with it loaded up?
Great fix and outstanding field engineering. That's some serious stress to have done that (or just bad metal during manufacture). KTM, any input?
Dear, could you write more details how you did weld chromomolybden? It is unbelievable!
Just Google it there are plenty of tutorials on the internet
Excellent “ in the field “ repair !!!
wtf!? No warranty from ktm?
Considering my last trip I will check my 1190 more in detail...
How the hell could this broke?! I am completely new to KTM and recently bought a brand new 1090 R. Wondering if this could happen too... So far I've trusted the guys from Austria of course. Btw, good job for your improvisation and fix.
Not sure how that would have happened but have got one of these so it worries me. Already had a problem with mine but have posted a solution video which is no where near as bad as this!!
My flirtation with possibly buying a KTM is over.
...and yet another buddy called me today saying his 1190 just cracked in the same place. Pics at the forum
Yes my friend with the 1190R (in my video) showed me your forum. It is way too common. I wish KTM would do something about it.
@@GreatwhiteADV what building year are you talking about?
The failure was uniform, so from the engineering standpoint, it would probably equate to being overweight or close to max with increased downward force while off-road. Further, when you are riding the rear did not appear to use the rear shock or travel down and rebound. Offroad settings usually mean you set rebound high, so this tells me the rear spring sucks, was not set properly, or is not rated for that weight.
Glad you fixed though, I love my KTMs and have never had an issue offroad on heavily loaded bikes on the same BDR routes you were on.
I know you know all of this, just trying to think of a way a uniform frame break would occur, I don’t think a a few isolated event is a design flaw, perhaps quality control issues though. Ride safe.
damn, wall these pipes is kinda thin...
What did you guys do!
Jump it off a building or something? 🤔😱
Is that why they’re so light ,because there is no metal in the frame . Could’ve meant death on the highway wow
Goddamn! It's looks like a bit thin and unreliable frame on 1190
Ya I was really surprised by how thin the steel was!
@@tylerastrope4549 More like a bicycle frame!
It's a piece of crap frame. Designed for 'tours' to the grocery shop and back.
Nah, I've got a '14 1190R with 30k miles on it and it's a beefy as heck frame. If I had to guess the suspension on it got bottomed out pretty dang hard to crack it, and then riding it fully loaded for miles and miles (without noticing the crack) until it failed in other places.
Jacob Alheid
Even if this is true it the frame shouldn’t crack.
It’s chrome molly.
The dealer should support you and get support form the manufacturer. Wrote to them. You should not be riding with a welded frame and the weld may crack again.
Cheers.
If you look at where the weight is slung it is too far back and definately caused the failure. I agree it should be stronger but it's not. Well, now it is. Great fix.
Oh man. That was brutal frame breakage. Nice to see the KTM back in one piece though.
I can see rear suspension has been changed ...
holy batshit, great im going to have nightmares about my 1190R now lol
What the hell ? something I should be concerned about? I've only got a couple hundred miles on mine. You jumping?
How many kg of luggage you had on it when it happened?
Maybe Around 25 kg plus 2 gallons of gas
My KTM is only a 300exc, but I've had some fundamental floors that I really wasn't expecting from the brand. So has my boy's 65cc...with an issue that should never have left the factory!! I still love the brand.. no one is perfect....
There just no way that could every happen to an unbreakable, awesome, perfect KTM. (sarcasm)
Great final fix though. Maybe KTM should hire you as an engineer?
50,000 miles on my KLR...not one issue, other than it's a KLR.
... other than it's a KLR :D
You made my day, bro ;)
Meh, did the same to a KLR650. Snapped the entire subframe off. Had no seat whatsoever ever.
Very impressive fix my man. both offroad and permanent.
And now every time I hear the center stand hit,I’ll think it’s the frame.
Wow dude nice job I had to sub after that
Did he even jump that bike how in the hell does a frame break like that ... I crash my wr 250f at almost 90 kms per hour and snapped my leg .... no damage to bike and now leg is better then ever
But your enduro bike weight 110kg... And is not loaded with ton of camping gear. That's the problem : contstant stress on the frame. But it's no excuse, at this sell price, you MUST NOT BE WORRIED ABOUT THE RESISTANCE OF THE FRAME. For me, the best thing is to contact KTM and work with them to solve this problem
@@jowenjv4463 good luck
@@AnyMotoUSA haha yeah, you're right. I think it's still worth a try ;)
Yes but WR250F is Japan bike - not European. That explains.
This was a fault on the early 10 -11 models , rectified now ......
You got an official link to his claim?looking to buy and want to be sure
Was getting ready to trade in my Ninja 1000 for KTM Super Duke today but after watching this I think I better look to Yamaha MT-10...so thanks for opening my eyes
M Aldridge glad you were able to open your eyes that is fantastic. You should also look into the Honda Grom they are bullet proof!
You won't be breaking the frame on the road
wow! maybe less rotopax next time? amazing fix tho
The frame gauge is so thin
wow, I would have called immediately KTM to show them that. Lucky you knew how to fix it. Looks way stronger now.
The main frame of my 2014 1190 Adventure-R with 24,000k's on it broke in exactly the same places as yours did. I was 7 days into a back country trip in the South Island of New Zealand at the time but I travel light (one 30L bag) and I weigh 81kg so I agree with your comments that your frame breaking isn't down to your bike being overloaded. I was riding along Skippers Canyon Road (www.dangerousroads.org/australia-and-oceania/new-zealand/55-skippers-canyon-road-new-zealand.html) when I noticed something wrong... I'm glad I wasn't doing any serious power slides at the time! I went the new frame route but I like the look of your rebuild and the gussets that you've put in, nice work.
This frame failure issue has me worried. Was your 30L bag strapped on the tail rack or on the pillion seat? Did you do any hard off road riding / jumps before the failure?
The bag was strapped across the pillion seat. It probably only weighed 10kg max. I was riding it like it's meant to be ridden (hard off road, across rivers etc.) but not doing jumps as such. I've ridden dirt bikes since I was 10 (I'm 49 now) and this is the first bike I've ever had snap in half on me. It's not a great look for a bike that is marketed to be ridden hard and personally I don't think it should have broken. Having said that at the end of the day sometimes shit happens. Anyone who has watched The Long Way Around has seen how many times the BMW's broke on that trip - I'm not picking on those bikes but it highlights that that's the way it goes sometimes when machinery is being pushed. I still love my 1190, when I'm not riding my 300 EXC I can take my wife out for a skid on the gravel roads, which she loves, and earn brownie points while having a great ride - that's pretty damn hard to beat :-)
Awsome resolution!
These days everything most be lighter,with serious problems wen you demand a lot from your gear, the new bmw gs 1200 habe also a lightweight Problem!
I would think KTM would be interested in your solution--it look like what should have been done by KTM when they built the bike! Outstanding solution and a fix to a known problem--uh.....KTM? You listening???
Epic everything! Nice fix!
I'd say your back end loading contributed to that for sure.....good adaptation though on getting yourself out of the woods.....
I'm a welder by trade and I can it,but to tear down the bike and put back together not even in my dreams. To pay someone to do that's a hefty bill. Hopefully that doesn't happen to my 2017 1090R.
What engine guards do you have installed on that? BTW beautiful job on the repair, amazing work!
Black dog skid plate and rumbux upper crash bars
Great repair absolutely we’ll done ✅
KTM should give you a new chassis or a new moto and compensation for damages.
Great job guys!
Great fix!
Hard to imagine if you don't have any strap with you
Are you sure this is not a Chinese made KTM? LOL
Chinese are able to produce a better and more solid KTM. This one must be defenetely from Austria! LOL.
Omg... Now i better buy a africa twin... Thanks for Video
DO it for sure!
KTMs are notorious for bad quality. They are the equivalent of Alfa Romeos - built to be the best but only for a short while. They win the Dakar year after year but you won't find many going around the globe.
they win the dakar exclusively because have a massive and solid mechanic team, they win the dakar, not the bikes.
That is very odd! These are bikes that have won the Dakar 16 - 17 years in a row! I think what went wrong is that buddy had way too much weight on the back, but also he had all that weight at the furthest point on the bike and with the ruff terrain, it broke.
Gaah! One of the few situations where solid ratchet straps will perform better than Rok Straps.
gusset! great "light bulb".... .......happy trails...
Why no help from ktm ie new fram ? Then beef it up good repair job tho lads 👍👍👍
We should learn to face this,great !