Stiffening subframe

16 replies to this topic
  • Barro

Posted August 29, 2005 - 02:13 PM


When an XR650R rear subframe breaks :D , WHERE DOES IT BREAK?

I want to stiffen the reportedly weak subframe and want to know what areas to pay attention to :D .

’03 XR650R

  • J_Daniels

Posted August 29, 2005 - 03:03 PM


My sub was bent when the original owner picked it up from the dealer; it took him a long time to notice and by then it was out of warranty. I guess it's very common. He used a long 2X4 thru it as a prybar, and it cracked slightly at the left upper mount. I haven't gotten around to welding it up yet, but I will be adding gussets to the upper and lower mountings to spread the load a bit.

  • Barro

Posted August 29, 2005 - 07:14 PM


Mine came with the "factory bend" option as well and I made it worse after and endo with a twist and a bad landing (the whole rear twisted 1.5" to the left) a calibrated 2X4 and some :D fixed it.

Now I hear that the frame has been known to crack at some points and I want to stiffen it while I have out. (welding some aluminum along bad spots.


  • x400r

Posted August 30, 2005 - 04:43 AM


go to

  • irondude

Posted August 30, 2005 - 08:20 AM


I gussetted mine where the rails met...then i added an extra cross-member.

Its stiff!

Cost me $20 at Welding Works in Orange, Ca.---he does the same for factory desert bikes...

  • Barro

Posted August 30, 2005 - 08:23 PM


I gussetted mine where the rails met...then i added an extra cross-member.

Its stiff!

Cost me $20 at Welding Works in Orange, Ca.---he does the same for factory desert bikes...


Where did you put the cross member? Maybe behind the bracket that has the seat mounting threaded holes?


  • Fingers

Posted August 30, 2005 - 09:06 PM


The SRC kit strengthens the rear fender but adds additional leverage to the subframe which will increase the likelyhood of its eventual breakage, especially if you add a rack/panniers. The DK version of the XR-650R has a fender brace somewhat similar to the SRC unit stock (used to support the taillight/turn signals). It likely can be special ordered and is a good fit and well made. Like the SRC unit it does not add extra support to the subframe itself. Gusseting the stock unit is the only solution for a stronger subframe that I can think of. I am running dirtbagz and a rear cargo bag with BD passenger footpegs, all mounted to the subframe. For street use it has proven strong enough but I would hesitate to go anywhere rough with a passenger or cargo loaded until I eventually mod the subframe to make it stronger.

  • irondude

Posted August 30, 2005 - 09:30 PM


I have both the strengthened sub-frame AND the subframe extender, with Baja Designs LED license plate holder--AND a custom bracket on top of the fender for my GPS antennae, dual running lights, Sentinal bracket, etc.

Works great!

I put the extra sub-frame cross member right next the the existing one--shaving a bit so it cleared everything.

I can pick up the bike by the rear fender now without issues.

I've tried other set ups--but for me they just couldnt take it. Either the license plate/brake light loosened up, or broke, or the sub-frame would bend.

The set up is very sano/beefy. That and a gusseted sub-frame is a nice way to go. Add in the BD LED brake light and things are good. The SRC unit has little holes for mini-turn signals that are also nice.

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  • Fingers

Posted August 30, 2005 - 10:22 PM


Irondude, did you do anything to strengthen the mounting locations for the subframe? That seems like it is the area of most concern.

  • olinmat

Posted December 10, 2005 - 02:31 AM


Please post pictures of your subframe solutions. Thanks.

  • bork

Posted December 10, 2005 - 06:36 AM


Is this for xr650 s only or as well a problem for xr600r ?

  • AzMtnThumper

Posted December 13, 2005 - 05:14 PM


Any pics....fellas? Irondude can we see that rear shot of your 650R again??

  • HawkGT

Posted December 15, 2005 - 11:56 AM


we need pics, please

  • bork

Posted December 15, 2005 - 05:57 PM


Is this for xr650 s only or as well a problem for xr600r ?

Well ??? does the xr 600r have a week spot for cracking too ?

  • AzMtnThumper

Posted December 15, 2005 - 09:57 PM


Well ??? does the xr 600r have a week spot for cracking too ?

I've heard of a few guys having problems around the steering stem area but I never had any with my 600. I'm not much of a jumper.

  • bork

Posted December 16, 2005 - 07:15 AM


I'm 300lbs ish & I'll keep my eye on sterring head. Thanks !!!

  • chicago650r

Posted August 21, 2007 - 06:59 PM


Hi. I am wanting to stiffen my subframe to be able to mount panniers and less

importantly carry a passenger. I would like to know what type of welding rod

to use for tig welding. I have 4043 and 5356 filler rod. Any suggestions? MM

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