Need help! Crack in my fork...
 

Ok, so, I've been riding my bike now since sept, and have only just realised, dont think it was there when i got it, that my fork has a crack in it, the pictures are off google that ive drew lines until it gets light and i can take a decent pic, but what are my options? It is straight on one side only and the other side has a small half crack.
Can i get a garage to weld it? or am i going to need a new fork? im in the uk and dont know how much theyd cost...

Pics
 

http://s24.postimg.org/knwvqmb01/T2e...Es_P_60_35.jpg

http://s24.postimg.org/4qy3twilt/GSG...ders_XT660.jpg

Found a pic of it I uploaded to facebook, here it is
 

Not sure if you can see it very well

http://postimg.org/image/fz5hwcvil/
http://postimg.org/image/fz5hwcvil/

I'd say, replace the forks. It may seem like it's still rideable, but it's a matter of time before more starts breaking and then you crash...

you can try looking for some fork bottoms on Ebay and have a shop put it together...

I wouldn't ride them like that; for peace of mind I'd replace the fork bottoms.
Looks like they've been overtightened, the pinch bolts only need to be 'pinched' up to stop the spindle turning, I think the torque settings are quite low.
The damage could have been done by a previous owner or heavy handed mechanic and the crack lying dormant. Replace asap !

As has been mentioned, it's a fairly common occurrence when the pinch bolts are over-tightened. There are lots of cases detailed in threads on the form on Rs, Xs and Zs. Here's just one:

http://www.xt660.com/showthread.php?t=13307&highlight=fork+cracked

I wouldn't risk riding it in that state. It certainly won't pass (or shouldn't pass an MOT) in that condition. Now you've advertised that you are aware of the fault on an open forum, your insurance company (should they get wind of it) is highly unlikely to pay out in an accident.

You can get this sort of thing repaired professionally - it is most definitely NOT a DIY job! Sourcing a pair of secondhand forks is probably the best way forward.

Maybe a good occasion do to a WP fork upgrade :)

WP Fork
 

What's the WP fork upgrade?

Complete rebuild and replacing stock fork legs with WP fork legs from a KTM. Needs some major work on steering head etc. There are at least three such builds partly documented on the forum. Probably more expensive, but might be worth comparing to the cost of stock fork legs that will give you the same crappy OEM suspension.

Welding
 

Is it worth getting it properly welded? I don't really want to be spending lots of cash of forks, and they seem a common problem so new ones may eventually do the same? Cheers