P500 Pioneer 500 roll bar failure

[HUCK]

I have a 2016 Pioneer 500 I bought new that hasn't been abused or crashed .
A few weeks ago I was headed out to go on a ride and I heard a rattle that sounded like it was coming from the top of the windshield on the drivers side . After pushing and pulling on everything trying to find where the noise was coming from I saw that the front (right-left} roll bar weld
had broken off from the left (front-back) roll bar .
I'm not knocking Honda , I love all mine from my oooold XR 200 to my Talon and all the rest in between .
I am wondering if anyone else has had a similar roll bar failure .
I am hoping that since it is the most crucial safety aspect of a SXS that Honda will make good on it and replace it but it's been three weeks since our local dealer contacted them .

 

[NTCPrezJB]

Wow! Tough to deny that’s just a product failure. Hopefully Big Red replaces your ROPS under warranty/good faith.

 

[Remington]

that sucks! But if u look at the brake, the weld is intact so your issue looks to be the bar itself. You can try and contact them about it, but its a 2016 and they most likely will not do a thing. Honda has bigger fish to fry. things like your location from say salt corrosion, some mud corrosion like in Georgia and Alabama can all be a cause.
if it was only a yr or 2 old, yes Id raise some hell. That said, If I was in your spot I would clean up the area good and weld it back together even stronger and be done with it.

 

[HondaTech]

What's up the flaking paint/rusty area there?

Looks like previous damage?

 

[HondaTech]

Wow! Tough to deny that’s just a product failure. Hopefully Big Red replaces your ROPS under warranty/good faith.

Yeah, that'll never happen

 

[HUCK]

that sucks! But if u look at the brake, the weld is intact so your issue looks to be the bar itself. You can try and contact them about it, but its a 2016 and they most likely will not do a thing. Honda has bigger fish to fry. things like your location from say salt corrosion, some mud corrosion like in Georgia and Alabama can all be a cause.
if it was only a yr or 2 old, yes Id raise some hell. That said, If I was in your spot I would clean up the area good and weld it back together even stronger and be done with it.

We are in a virtual 0 rust climate . It's just a ROPS failure plain and simple . Is it an easy fix ? Absolutely . We'll see

 

[500oneer]

We are in a virtual 0 rust climate . It's just a ROPS failure plain and simple . Is it an easy fix ? Absolutely . We'll see

Not rust free in pa on my 2015. This is on the passenger side,the drives side has a some surface rust. Bottom of the pipe seems solid.

 

[HUCK]

View attachment 356577Not rust free in pa on my 2015. This is on the passenger side,the drives side has a some surface rust. Bottom of the pipe seems solid.

I had to google RUST to see what it is .

 

[Remington]

We are in a virtual 0 rust climate . It's just a ROPS failure plain and simple . Is it an easy fix ? Absolutely . We'll see

Will see? About what, how your good your weld is?

 

[hondabob]

It looks like Honda has had some failures. If there is good weld penetration, then the added gusset is a good improvement. All the added gussets at the bends on improved 2022 roll cage are more to prevent bending in a roll over. The 2022 500 and 2021 and 2022 520 have the new roll bar frame section with the gusset. The rear roof roll bar section has an added gusset too. There is no pre-load where the weld failed so the stress must be from uneven terrain causing one wheel to lift. The failed roll bar section cost is $285,22 for the improved 2022 roll bar, the older roll bar without the gusset cost is about $10.00 higher. Huck and I have the same local dealer and after 10 days it doesn't look they will get it covered but customer relations might. We compared the roll bar on his 500 and my 520 and it looks like the only difference is the added gusset.

 

[Jerryg]

JAH