anyone else have problems with the tie rods and steering knuckles? this is #5 for me, getting ready to add gussets. and see if that helps.

Yep. Are you temping it after you get it straight?

[2015 Z Force 800 53/Trail EPS]

There has been a lot of reported issues with that exact same thing on the 2018+s. That...should not be happening.

yes I got it straightened out the best I could in the press. I'll post pictures when I get it welded. I plan on just testing it out on a bent one and if it holds up I will get new ones and weld those. It sucks having to replace them after almost every ride. I always have spare tie rods on the trail, but if theres any bend at all in the arm it will ruin the tie rod in a short amount of miles. if this doesn't work then I will be fabing some of my own knuckles and A-arms with heim joints.

Don't make it to strong. It's only as strong as it's weakest link. Tie rod ends are cheaper then a new rack. Jmo. I tempered mine after we got it straight and haven't had a problem scents.

That has been in the back of my mind too. Where are you riding? I'm in Colorado. The rocks beat everything to death. I'm at the point where I'm going to do whatever it takes to make it strong enough to ride the way we ride. Even if that means installing someone else's rack.

I'm on the east coast. Not so much rocks but deep ruts is what is causing our problems. I know rocks are unforgiving but the side of a 3 foot deep rut ain't no joke either. You still haven't answered my question. Are you tempering the knuckle after you heat it? Or are you bending it cold?

Sorry didn't notice your question, but I straighten it cold. Plan in heating it to 100 then welding with 7018 rod. Per SFSA manual.

I miss riding in the mud. Lots of good memories, I grew up in Indiana and took several trips to the Hatfield McCoy trails in West VA.

Once it's bent it has lost its strength. If you are bending it back cold you are weakening it more. Heat it with a touch and bent back to where you want it and put it in a bucket of oil and let it cool this will put the strength back in the steel. That's what I did and it hasn't bent again. Are you saying this is the 5th time you bent the knuckle or the 5th tie rod ends?