What caution needs to be followed?

[Idaho]

If a guy was to weld on the bike frame what caution needs to be followed to prevent damaging any of the electrical system? Particularly concerned about the ECM. I would think at least disconneting the battery would be a good idea. Beyond that I have no clue.

[VulcanE]

Bud, I would disconnect the ECM, and place the ground as close as possible to where your going to weld, between any electrics and the welding location. That being said, where you weld on the frame is probably more important. Welding develops a lot of heat, and the heat will anneal the strength out of the location your welding in, so if it's in or near a "stress point", I wouldn't even consider welding. I've thought a few times about welding two bosses on the tube of the swing arm (like the Classic and Mean Streak) so I could mount the type of chrome drive shaft cover they use on mine, but, I'm concerned about weakening the swing arm.

[ringadingh]

Disconnecting the battery is a must Id say, you don't want to gamble on frying the ecm.

[Cajunrider]

What Cliff said Bud.

[Idaho]

I am thinking about filling in the hole in the frame where the sidestand bolt is reamed out then drilling it back out so I have a nice round hole again. I will also weld the bolt shoulders and grind that back down into shape. That way I can put my original springs back on and keep the sidestand lubed up.

There is a lot of electrical stuff in that area and I wonder if there is a possibility that I could weaken the frame there as Cliff noted.

[ringadingh]

I woudn't worry about weakening the frame any, just be careful that you don't melt any wiring or other stuff.
Can't you just drill the sidestand hole out a little and install a larger diameter bolt?

[MAS Tequila]

It's been done before.

Disconnect the battery and don't try to do the whole weld at once very quickly.

Once the battery is diconnected the ecm will not have both pos and neg connections.

MT

[cactusjack]

I'm curious how you plan to drill the mount. Just a hand-held drill? Kawasaki really screwed the pooch with that design. They should have made the entire mount removable and replaceable. Mine was pretty out of round when I crashed her.

[Idaho]

I would just spot weld around the ovaled out hole then use a hand drill to clean out the hole. Not planning to weld the hole entirely shut.

[Jared]

Originally Posted by VulcanE

Bud, I would disconnect the ECM, and place the ground as close as possible to where your going to weld, between any electrics and the welding location. That being said, where you weld on the frame is probably more important. Welding develops a lot of heat, and the heat will anneal the strength out of the location your welding in, so if it's in or near a "stress point", I wouldn't even consider welding. I've thought a few times about welding two bosses on the tube of the swing arm (like the Classic and Mean Streak) so I could mount the type of chrome drive shaft cover they use on mine, but, I'm concerned about weakening the swing arm.

You mean a chrome shaft cover like this? :)

[VulcanE]

Jared, sorta like that, that looks like a Cobra shaft cover. I bought a Cobra cover a few years back, and the only way it would fit is if I cut the end of it to allow for the gusset on top of the tube at the end where the final drive bolts on. The cobra site said it would fit a 1500 or 1600. It will fit the 1500 with no modifications (they don't have the gussets). If I buy something that is supposed to fit, I don't want to have to butcher it to make it fit, so I got my money back on it. The Classic and MS cover is held on via 2 screws going through the cover, and screw into bosses that are welded to the drive shaft tube.

[Jared]

Originally Posted by VulcanE

Jared, sorta like that, that looks like a Cobra shaft cover. I bought a Cobra cover a few years back, and the only way it would fit is if I cut the end of it to allow for the gusset on top of the tube at the end where the final drive bolts on. The cobra site said it would fit a 1500 or 1600. It will fit the 1500 with no modifications (they don't have the gussets). If I buy something that is supposed to fit, I don't want to have to butcher it to make it fit, so I got my money back on it. The Classic and MS cover is held on via 2 screws going through the cover, and screw into bosses that are welded to the drive shaft tube.

I am not too sure what brand it is. Probably a Cobra. It was given to me and I did have to hack the two lower corners to make it work.

[ringadingh]

My chrome shaft cover is held on with two rad clamps, I don't know what brand it is but assume its a F&S part.

[medicaldawg]

Originally Posted by Idaho (High Plains Drifter)

I am thinking about filling in the hole in the frame where the sidestand bolt is reamed out then drilling it back out so I have a nice round hole again. I will also weld the bolt shoulders and grind that back down into shape. That way I can put my original springs back on and keep the sidestand lubed up.

There is a lot of electrical stuff in that area and I wonder if there is a possibility that I could weaken the frame there as Cliff noted.

er thats a cliff note hahaha.

I personaly have been welding on another bike. I unplug all electronics. Spot weld as stated to keep heat as low as possible.

[macmac]

Can't add nuthin......