Confirmed reports of Busa subframe failure - IF YOU\'VE GOT LUGGAGE TAK

I bought this big bike, over a smaller bike, because I wanted to ride two up and carry luggage. Fuel filters, ok. Cam chain, maybe. Frame breaking, if a real problem, not acceptable.
 
I've spoken to reps in person from both Givi and Corbin, looking to make this into a real sport tourer. I was told by both reps that neither company currently offers hard luggage for the Busa, and both cited the same reason: they're not comfortable with the strength of any mounting points, citing that the subframe is light weight, with difficulty in finding what they consider sufficient mounting points. Not that it would not be possible, but in those rare cases where someone would stuff too much weight in a side bag, it might cause a safety problem.
I'm no engineer, but maybe the bike is designed to handle passenger loads, lightweight subframe withstanding, but it does not work well having to drill into the frame to mount luggage. Not drilling, like the manual says to not do.
Anybody got ideas for soft side luggage?
 
You know, now that I look at the subframe with all the plastic removed, it does looks pretty wimpy. Luckily my wife has her own bike. :)

Oh, and I'm wondering if any of these bikes that failed had aftermarket exhaust, specifically 4 into 1 systems, because it seems that the subframe would get some stiffening due to being linked with the exhaust thru the two back footpeg brackets. Remove and and you loose some of this.

[This message has been edited by Thradar (edited 14 July 2000).]
 
The initial point of failure from what I've seen are the cast alumunim fittings that are welded to the top front tubes. The fittings appear to have just cracked. Could be a casting or design problem. Looks like a safety strap could be designed but, I hope Suzuki comes out with a better fix quickly. Even if they do,however it will take time and their recommendation may be to not ride it until the fix is completed for liability reasons. Even if the problem only happens with extra luggage it means this is a weak spot in the frame. The Suzuki manual page 48 states "bolt-on-accessories that do not modify the frame in any way may be installed, provided that the GVWR is not exceeded".
 
Don't sweat the luggage. Use A tank bag... throw in a T or 2 , 2 pairs socks, 2 pairs of underwear, 1 extra pants, tooth brush, and the hardware of your choice(Colt Combat Elete here) . Did 4 day trip a few weeks ago. Used a 17 liter bag. Even took my camera. NO PROBLEMS! Love traveling light.
 
I am ok with filing a complaint with the transportation folks, however my concern is should I continue to ride w/ my 8 year old son and other passengers?

Has anyone spoken with Suzuki?
 
My Busa is a one up machine only, so I'm not too worried about it since the load from the riders seat goes right into the main frame and I almost never strap anyting on the back seat. BUT, if you are someone who rides two up a lot, I would think about stopping until Suzuki figures out what's going on.
 
Glad to see others are taking this as seriously as I am. Despite my earlier jokey posts, I feel that my touring holiday, two-up with luggage may be in jeopardy.

I agree with Canuckbusa, afterall, the bike is supposed to be a sports tourer.

Although there have only been a few reported cases of this happening, it's not the sort of thing you want knawing at the back of your mind every time you go out on the bike.
 
How do you 'fix' a frame failure? The only way I can see doing it is by replacing the frame. Bolting it? Welding it? Replacing it. New frame=new bike?
Lee
 
In my opinion, the bottom line is this: It doesn't matter whether it was soft luggage or hard, one-up or two-up, I paid big bucks for a top of the line bike. I demand that it be safe and reliable under all conditions it is designed for, and obviously it is not. I personally have not had problems with my bike, but this list of stuff...fuel filter, chain tensioner (failing on '00 models too now) and the subframe breaking under load?!?! Did Suzuki endanger its customers to save weight? Have they gone to market with a lemon? I want to love this bike, but I'm losing confidence in the bike and in the company now. I'm afraid to ride 2-up and I shouldn't have to be.
 
people who are suffering from the broken tail section need to be letting the nhtsa know about it. i called them last week and not 1 single complaint about broken frames. if the nhtsa doesn't hear about it, they can't force suzuki to do anything about it!!!! their number is (1-888-327-4236). letting suzuki fix it without the government knowing will not get any recall action!!

big papa
 
I got a phone call at work today from Givi, saying they recommend taking off the luggage until the safety issue is settled with Suzuki; I am supposed to get a letter in the next few days. Its not a recall... yet.

If you take off the seat, and push down on the passenger seat, you can see the subframe trying to spread the main frame members like a wishbone... visible flex without much force. It all looks pretty robust, but that lateral flexing might lead to cracking... If Suzuki admits a flaw, I bet the "fix" is a cross-brace where the seat attaches to the frame. Those welded alloy lugs should be plenty strong in tension, but lateral flexing may be a different story!

This bike has a stated carrying capacity of 410 pounds; thats a 205 lb rider and a 205 lb passenger; hard to see how Suzuki can put all of the blame for this problem on luggage.

Finally, notice all the failures in the UK? And how a bunch of the photos showing the fractures have a battery with silicone sealer all over the battery terminals? Maybe these guys live near the ocean... salt air! Corrosion! (I know, a real stretch...)

-(un)happybus
 
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