New rear subframe and Givi TopCase. Fixing and farkeling...

[PatM]

...the beast

Not sure if this is in the right area of the forum, mods feel free to move it.

Last summer, during a trip to the Canadian Maritime region, I had the rear subframe break unexpectedly. Yeah, I know, I should have listened and not overload the top case.




To finish the season I used JBWeld and hose clamps and removed the top case.


Removing the subframe isn't a big issue, just remove all the screws and plastic panels. Note where everything goes and take lots of photos.


New subframe in. New Givi TopCase support.

[extrememarine]

Nice Job - How was the top box mounted (type of plate, etc.) to cause that type damage?

Did you explore having it welded vs. replacement cost?

Thanks for sharing and posting this as a reminder about load capacity.

[fencer]

Nice Job - How was the top box mounted (type of plate, etc.) to cause that type damage?

+1

[Geosci]

Just curious... how overloaded was the top case?

[PatM]

The top box was installed on an aluminum plate held by the three bolts at one end.


It's probably fine if you just use it as a simple rack for the occasional travel bag. I usually carry my laptop, camera, maps, water bottle, gloves, etc. in my top case. On long trips, it's always full, I'd say a good 20 - 25 lbs. Maybe more...
The problem is that it is held at one end by the three bolts and the rest is unsupported. With the bad roads up here, it would always flip - flop while under way, with the top case on, which I believe caused metal fatigue.
I replaced the subframe instead of fixing it. Not cheap but I got a very reasonable price on it. I'm not convinced it wouldn't break right next to any new welds.
The mounting kit is the Givi SR357 kit. It's much stronger than the plastic grab handles.

[fontanaman]

Thank for posting. Like you I have and 09 and a Givi Box. I rarely use the topcase. Based on your report I am going to keep load low. If I need more pack more stuff on during long trip I will put lash a bag to the rear seat.

This bike is rate for about 440 lbs of carrying capacity. It is really hard to tour two up when I can't load up the top case. My wife likes to take stuff.

I have a Russell seat and I believe the wide seat will rub or interfere with installation of the SR357. I will have to do some more research.

[Geosci]

I just received my Russell seat and have the Givi SR357 installed as well. The Russell pillion is a little snug along the sides where it meets the SR357, but they still function together.

[fontanaman]

Since my last post I have purchased and installed a Givi SR 357. Much sturdier than the stock plastic unit.

[PatM]

New farkles: I replaced my aux lights from Martin Fabrication, PIAA knockoffs. Mine were black with blue lamps

with the real stuff: PIAA 1100 LED

The MartinFab lights were 35 Watts Halogen but were only good to be seen. The light beam was at best weak and the blue bulbs unreliable.

The PIAA 1100LED give off far more light even if they're using only about 3 Watts each.
I use aux lamps primarily to be seen rather than to see but this is an improvement.
I reused the MartinFab brackets instead of the PIAA supplied ones. The lamp cases are the exact same size and use the same screws to mount.