1200GS Pannier disassembly

[Engineer]

I need instructions (illustrated) on the dis-assembly and re-assembly of the 1200Gs Vario panniers. The mechanism has become jammed and I am going to attempt a fix.

I am sure that I saw the instructions either on this site or the American one - but I can no longer find the right thread.

Can anyone point me in the right direction?

 

[cheap'n'cheerful]

Hi Engineer
I have the instructions in word format if you pm me with your e-mail address I will e-mail them to you
Cheers C'n'C

 

[Mucky Helmet]

Before you start....

Before you go taking the Varios apart, have you tried lubricating the bits that slide up and down?

I had a similar problem last week with my top box, very difficult to expand and collapse, would stick hallfway or in one position. I was about to start taking the Vario apart but thought I'd have a go with some silicon spray first. Whilst collapsed, I turned the topbox upside down and sprayed copious amounts of silicon lube inbetween the plastics, allowed for it to run through, worked the mechanism and repeated a few times. I also sprayed the gears inside and applied more to the outside whilst expanded and kept working the mechanism.

What I have now is a very shiny Vario topbox with a silky smooth mechanism. Very glad I didn't have to take it apart.

I used Maplins silicon spray with PTFE as that's what I had to hand. I figure GT85 will probably do the same.

HTH
Helmet

 

[Engineer]

Before you go taking the Varios apart, have you tried lubricating the bits that slide up and down?

I had a similar problem last week with my top box, very difficult to expand and collapse, would stick hallfway or in one position. I was about to start taking the Vario apart but thought I'd have a go with some silicon spray first. Whilst collapsed, I turned the topbox upside down and sprayed copious amounts of silicon lube inbetween the plastics, allowed for it to run through, worked the mechanism and repeated a few times. I also sprayed the gears inside and applied more to the outside whilst expanded and kept working the mechanism.

What I have now is a very shiny Vario topbox with a silky smooth mechanism. Very glad I didn't have to take it apart.

I used Maplins silicon spray with PTFE as that's what I had to hand. I figure GT85 will probably do the same.

HTH
Helmet

Thanks I have done this in the past and it works well - the problem this time is that the RHS pannier took a knock and the expanding mechanism has jumped a tooth on the gear wheels or something similar so I have to dismantle them.

 

[Yankee Lima]

Vario pannier issues expanding mechanism sticking

Hi

The mechanism is very stiff to the point of being inoperable and I don't want to be heavy handed and ping a tooth of a gear.

Does anyone on here have a set of instructions or manual covering the maintenance of 120GS vario panniers they could mail me.?or point me in the direction of a thread dealing with this problem?

rgds

Yankee Lima