My R100GS steering stops, specifically, one side, has been sheered off (the alloy part, not the steel bit on the frame) in a previous fall and now the forks (bolt) hits the fuel tank and is denting it.
Does anyone have a suggestion for a heavy duty replacement?
Thanks
Scott

Any repair will involve at least partially disassembling the front fork top so that you can access the broken off stub area. The only two options you really have is to either buy a new top triple clamp (expensive) or have a small block of hard grade aluminum welded in place of the missing stop- less expensive, but involves a bit of sweat equity on your part.
Obtain a small piece of flat aluminum about as thick as the stop is tall , you have quite a bit of vertical clearance there, and use a hacksaw, a file and a die grinder if you have one to shape it so that it fits in the arc of the steering head . The stops are rather flimsy, not up to a good whack ,as you found, so notch the aluminum to fit around the remaining stub. You can extend it as far as the bosses holding the key and steering lock body wiith clearances left for the welding to same. Remove the steering lock /key body and any plastic bits, sandpaper away all the paint and coating to expose clean,bare aluminum. Have the aluminum surface that contacts the frame stop a bit longer than you need in case after welding you need to file it off a bit to get into square contact with its steel counterpart. When after all this filing, ,measuring and fitting you are satisfied it is a decent fit take it to a welder to get it stuck together.Test fit, final tweaks ,paint, reassemble.Sounds like a project.

__________________
http://advrider.com/index.php?thread....207964/page-5 then scroll down to post #93

... or, you could have aluminium welded back on.

__________________
Cheers,
Peter.

Europe to NZ 2006-10

You can fit two rubber stops on the flat plate attached to the steering stem. (The right plate is the one where the frame number is punched)
You can get these rubbers from HPN Germany and is very inexpensive and very effective. In fact they used this on the rally bikes and they remove the original steering stop of the frame when they do the frame modifications. These rubbers are glued in place using superglue and you do not need to strip anything to install them. They also act like shock absorbers instead of the usual metal on metal when the bike fall over or even when the handle bar is left to fall to the side.
HPN Motorradtechnik GmbH
They are so simple if you know what they look like you could make your own.

This is what the rubber steering stop looks like. Simple, effective, cheap and easy to replace without stripping anything. I bought extras for spare but I am sure you can have your own made, the rubber must be hard though and is glued on by using Cyanoacrylate or Superglue.