I had a wreck last year and my road* went down hard on the left side (I discussed this in detail in another thread). Well, my insurance company spent $6500 fixing the bike to get it back to like new (it was only 4 months old at the time of the wreck). But they missed a broken fork stop that I just recently noticed because the forks turn so far to the left that the passing light mounts banged into the tank and dented it one day a few weeks ago when the bike was parked. The insurance guy met me today at the yami stealer that fixed the bike and admitted that he should have caught the broken fork stop when he first looked at the bike - because the fork stop is considered part of the frame they would have totaled out my bike and I would have gotten a new one. What I need to know from some of you roadie experts out there - is it possible to repair the fork stop and if so will welding on the frame to repair it weaken any other part of the front of the frame? I'd really appreciate some input on this guys -thanks.

Hi Bigdawg56,
Liability is going to be the issue. That is why the insurance company would total the bike and that is why you will have trouble finding somebody to weld on a new tab.

I have done it several times on my own frames when changing necks or raking the frame. It used to be pretty standard to weld the necks, but the frame materials are much different today.

If you can't find someone to weld a new one on for you, there are alternatives. You can drill and tap and use the head of an allen bolt or bolt on a tab, but you have to watch the length of the bolts and use plenty of locktite.

Just my 2 cents worth.

John

Grind down the remaining part of the stop until it's smooth and flat as the surrounding tree. Buy a 3/8" SS bolt Allen bolt, 1" long, and a SS spacer, 1/2" long, to fit. Drill a hole in the fork excatly where the stop was and tap the hole for the 3/8" bolt. Polish the bolt head and spacer. Put the spacer on the bolt and screw the bolt into the tree. Cover the top of the Allen bolt with a chrome insert.

Doc

Thanks for your input jvcexc and doc but i should have been more accurate in my description - the part of the fork stop that is bent (and almost broken off) is the center part that is actually welded to the neck of the frame- is there any way to fix that other than welding on a new center stop?

Hmmm ..... I don't think so.

Behind that area is the lower neck bearing.

Doc

could you strip the neck down, remove the bearings and then weld the stop or would the heat distort it too much?

His question was "other than welding".

.... but ya ... you could do that if you have a good welder.

The tab does not normally have lot of force exerted on it.

Doc

But the question remains is - The adjuster missed it and should have.........
1. will they now still insure this bike even though it clearly has a condition that would have totaled it?
2. Only if yes to one are they going to fund the repairs that they were obliged to do in the first place instead of providing you with what they would classify as a safe bike.
3. they use the fine print in the policies to thier advantage most of the time. well go slow, get advise and it is your turn to use the fine print my friend.
Good luck
Dearman

A good welder could easily weld that tab on without distorting the neck. If you TIG weld it there is much less heat than arc or MIG (wire) You should remove the forks and bearings to be safe. I believe it shouldn't be your problem....
If it was my bike and I HAD to fix it I would just TIG weld it in place with the fork on and everything but, I have been a welder for 15years too

Steven