Broken subframe for topcase

[JWHITE518]

I noticed that my topcase was bouncing around way too much. Investigation revealed that the two arms that come out of the rear cowling and support the luggage rack had broken off. I actually suspect that one of them had been broken for awhile, because it's been bouncing and rattling for awhile. Finally the other gave up the ghost.

The break happened right where there's a cross brace, sort of a "shelf" that runs up and over the two frame tubes. If you remove the rear cowling you can see it clearly. Or look under your passenger seat, where the toolkit and owners manual are. There's a flat shelf of metal up high. Right under that, the subframe bars pass through and out to the back of the bike. The breaks were both right where the bars come out of that shelf.

Rather than order and wait for a replacement part, I rode to a local welder. He repaired the breaks, and then welded a reinforcing support under the break area so it doesn't happen again. I spray-painted the welds with black rustoleum, and now I'm back in business. Sorry, no photos, I just wanted to get the job done.

What can I say? Weird.

 

[51042]

I had the same problem on my R1100RS. It broke at the same place. I used a 5 inch length of water pipe of a size that fit perfectly inside the broken tubes. Inside each piece of water pipe I hammered in an equal length of solid threaded rod. As the rod was forced inside the water pipe the threads peened over for a snug fit. Next I covered the lengths of water pipe with JB Weld and pushed the broked subframe parts over the coated pipes. After wiping off the excess, the JB Weld dried for a perfect airtight and extra strong tail section.

 

[REBECCAV]

Huh. Thanks for posting about this. I have heard of several broken subframes lately - not necessarily on BMWs. I wonder if it is related to the amount of crap -er- necessary items packed into a topcase.

FWIW I recently ditched my BMW topcase and mounted a much smaller Pelican case.

 

[jdiaz]

FWIW I recently ditched my BMW topcase and mounted a much smaller Pelican case.

And stop carrying all that makeup around.

 

[cjack]

Huh. Thanks for posting about this. I have heard of several broken subframes lately - not necessarily on BMWs. I wonder if it is related to the amount of crap -er- necessary items packed into a topcase.

FWIW I recently ditched my BMW topcase and mounted a much smaller Pelican case.

Back in the airhead days, breaking a rear sub frame was common. Even without a back box but with a tent etc. back there. We used to carry a couple of short angle irons and some hose clamps to clamp the tubes back together to get home.
Speaking of carrying stuff...
I was looking on the IBR site and noticed a sort of "recommended tools to carry" list. It was about 10 feel long. I didn't see a lathe or drill press, but it was pretty impressive. I got to wondering just what kind of tools some riders carry. Especially when they ride thru the night or in lonesome places. I noticed years ago that mostly the parts riders carry are the parts that have failed on them once a time ago, or that they heard fail. Sometimes that works out, but usually it doesn't. I used to carry an extra innertube, but after several years of not using it, I got it out and it was sort of worn out from carrying it. Useless. Now I carry a valve stem. Tubeless tires. Heh.
So BG, do you carry one of those little valve cover donut gaskets?

 

[REBECCAV]

And stop carrying all that makeup around.

Yeah, that and the curling iron.

So BG, do you carry one of those little valve cover donut gaskets?

Nah, but I do carry a kit to fix a flat including an air compressor, tool roll, spare alternator belt, clutch and speedo cables, 5 kinds of bulbs (and 2 ea), multimeter, fuses, gas siphon... I'm probably forgetting something. All that is in a sidebag though - the topcase gets lighter weight stuff.

 

[cjack]

Yeah, that and the curling iron.


Nah, but I do carry a kit to fix a flat including an air compressor, tool roll, spare alternator belt, clutch and speedo cables, 5 kinds of bulbs (and 2 ea), multimeter, fuses, gas siphon... I'm probably forgetting something. All that is in a sidebag though - the topcase gets lighter weight stuff.

Ok, paranoia is setting in. I just set out my AirMan tire pump for the trip to WI and Colorado.

I heard once that Paul Newman travels with no luggage. Sends someone out for a clean shirt when he gets there. I was thinking of the feeling of freedom that must bring.

Riders used to ask me what the ridiculous left saddlebag on the K12RS would hold that was useful. I usually answered an AMEX card.

 

[JWHITE518]

Yeah, that and the curling iron.


Nah, but I do carry a kit to fix a flat including an air compressor, tool roll, spare alternator belt, clutch and speedo cables, 5 kinds of bulbs (and 2 ea), multimeter, fuses, gas siphon... I'm probably forgetting something. All that is in a sidebag though - the topcase gets lighter weight stuff.

Will you be using a laptop for the IBR? And if so, which one, how small is it, and how do you pack it?

 

[cjack]

BTW, in case anyone is interested in how well it works, we are using a Verizon broadband internet card (in a 12 inch Averatec). Internet many places that we have Verizon cell coverage. It works very well for us when there is no cable, dsl, or wireless.

 

[jdiaz]

Nah, but I do carry a kit to fix a flat including an air compressor, tool roll, spare alternator belt, clutch and speedo cables, 5 kinds of bulbs (and 2 ea), multimeter, fuses, gas siphon... I'm probably forgetting something. All that is in a sidebag though - the topcase gets lighter weight stuff.

I would bring an oil sight glass. They don't pop out often, but it'll end your ride if it does.

 

[REBECCAV]

I would bring an oil sight glass. They don't pop out often, but it'll end your ride if it does.

Should I carry a spare even though I replaced the original sight glass in July 2005?

Will you be using a laptop for the IBR? And if so, which one, how small is it, and how do you pack it?

Yes, I have a POS Dell that I use for rallying. It is normal size. The laptop lives in the (padded) Pelican case topbox along with other rally essentials like rally paperwork, maps, camera and film. Sorry for the hijack Jerry and good luck on the 1088 this weekend!

 

[JWHITE518]

Sorry for the hijack Jerry and good luck on the 1088 this weekend!

I hadn't even noticed the hijack. We're talking LD rallies now, way more interesting than the original topic! I look forward to seeing your Pelican setup in STL.

 

[cjack]

Should I carry a spare even though I replaced the original sight glass in July 2005?


Yes, I have a POS Dell that I use for rallying. It is normal size. The laptop lives in the (padded) Pelican case topbox along with other rally essentials like rally paperwork, maps, camera and film. Sorry for the hijack Jerry and good luck on the 1088 this weekend!

I think so. They are small and can be put in the mojo bag preventing yours from popping out.
Why did you replace yours. Fogged? It's not a very good (reliable) design, but at least they can be popped back in easily.

 

[DavidEBSmith]

I broke the same subframe in the same place on my RT at about 70K miles. Too much stuff in the topcase. So I got a bigger topcase.

On the sight glass question, I carry both a spare sight glass and a rubber expansion plug (1 1/2" as I recall) from the auto parts store.

 

[REBECCAV]

I broke the same subframe in the same place on my RT at about 70K miles. Too much stuff in the topcase. So I got a bigger topcase.

On the sight glass question, I carry both a spare sight glass and a rubber expansion plug (1 1/2" as I recall) from the auto parts store.

Welcome to the MOA Forum EB!!

OK fine, I'll get a spare sight glass which will ensure that I never have a problem with it. The original sight glass was replaced as a precautionary measure before the 05 IBR. Is the rubber expansion plug to fit the sight glass?

 

[DavidEBSmith]

Yah, the idea with the expansion plug is that you don't have to worry about getting the sight glass to seal right. You just plug in the plug and turn the little nut that tightens it and it's in.

Of course, you then can't obsess about the oil level in the sight glass, but that's probably a good thing for most oilhead riders.

And by carrying both the plug and the sight glass, you're doubly protected from ever having any sight glass problems.

 

[JWHITE518]

OK you've got me wondering now. What's this expansion plug you're talking about?

(and we're way OT here but who cares!)

 

[REBECCAV]

OK you've got me wondering now. What's this expansion plug you're talking about?

Ditto. Do I go to Auto Zone and ask for a 1 1/2" expansion plug? Can you post pictures?

 

[tdomek]

The plumbing shop may be a better source for the plugs these guy's are talking about. Here is a pic of the type I carry and have used for many things over the years:



Good luck,

 

[cjack]

The plumbing shop may be a better source for the plugs these guy's are talking about. Here is a pic of the type I carry and have used for many things over the years:Good luck,

Wait a minute!! How does this fix a broken subframe?