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Discussion Starter #1 (Edited)
Broken Frame -Any one had this happen to you

So i went to change the carb yesterday and took all the plastics of and found my frame was broken. Last month i did feel different riding. Has any had this happen. Anyone added and cross members or gussets to these frames. There is no new frames available from the dealer. So have to get it fixed.....or buy a used one, but shipping sucks..
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Get the welder out and start putting some pieces in there.
 

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Discussion Starter #3
I'm striping it down to the frame. Time for a full rebuild.

Does anyone have pictures of the Rath racing gusset kit installed. I cant find any kits for sale.
 

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Is that a top tube broken? I can't tell from the picture, what is mounted to the broken tube?
 

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From what I have seen on utility 500's the frame breaks like that are causes by jumping.
 

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I have broken 3 Sportsman frames many times. I believe the frames get fatigue from twisting.

Have seen pretty much all utility machines with frame breaks. Can-Am, Polaris, Suzuki, and Kawasaki come to mind. Not a big deal just gusset it and weld the frame back together.

I happen to have a good friend that is an outstanding fab guy.
 

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Poor design, look where the frame broke in the picture. It cracked just ahead of the thread insert that's welded into the frame. They drill a big hole in the frame, and wonder why it broke?
 

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i have seen it twice and i have broke an outlaw frame, the rath gussets are near the rear shock mainly but just gusset the hell out of it so you dont have any issues
 

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Discussion Starter #9 (Edited)
The frame broke on both sides next to the top motor mount bolts, and the front by the lower A-arm mounts also top shock mount cracked.
Taking the frame over to a sand blasters then the fab shop to get it repaired and some major gussets and a few more x members in the front
Get the frame powder-coated
 
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