1992 R80GS Refresh

[kirby morgan]

Check the underside of the toolbox. There should be 2 holes that align with two rubber grommets on the frame. Press the toolbox into these rubber bungs to secure the toolbox.
Battery sitting too high or too tall ? Also there should be a circular rubber bung underneath, this sometimes sits ontop of the battery rubber securing straps and stops the seat from locating correctly.

 

[nicholsonj2252]

My seat fits with toolbox and cover. Are there different depth toolboxes?

Not sure , there is only one listed in the parts diagram ? I'll have another go at fitting seat with the lid in place , it may be me just being thick LOL

 

[nicholsonj2252]

Check the underside of the toolbox. There should be 2 holes that align with two rubber grommets on the frame. Press the toolbox into these rubber bungs to secure the toolbox.
Battery sitting too high or too tall ? Also there should be a circular rubber bung underneath, this sometimes sits ontop of the battery rubber securing straps and stops the seat from locating correctly.

Toolbox is correctly sat in the two rubber bungs at the rear and there is a rubber bung in the front underside of the tray that sits on the top of the battery . I'll check it's not sitting on top of one of the rubber retaining straps

It's a new Motobatt MBTX30U battery that was listed as being for this bike

 

[B Murr]

Not sure what the difference might be but my battery is an MBTX30UHD.

 

[nicholsonj2252]

Not sure what the difference might be but my battery is an MBTX30UHD.

So is mine when I have checked , HD apparently stands for Harley Davidson and refers to the black casing colour rather than the usual bright yellow

 

[B Murr]

I'll check to see if I left out that spacer.

Just looked no spacer

 

[nicholsonj2252]

Sorted it - I had fitted a brand new bung into the toolbox (well actually the whole toolbox is new as the old one had holes cut in it)

When I checked the bung was not sitting on the rubber retaing strap but there was a height difference front to back in the tool tray position relative to the rear sub frame top member - some 10mm

Trimmed 10mm off the rubber bung (it was about 20mm long originally) to bring the tray level , re-fitted the lid and hey presto seat fits no problem

Not sure if the bung has been supplied incorrectly or if the battery is higher but anyway all fits fine now

 

[kirby morgan]

Bike looks great. A credit to you. Like all your bike refreshes ��

 

[nicholsonj2252]

I'll check to see if I left out that spacer.

Just looked no spacer

Yes my battery has no plastic spacer under it , the issue was the rubber bung that pushes into the underside of the toolbox

If you get a chance let me know what height your rubber bung is , mine was about 20mm and I've had to cut it down to 10mm

 

[B Murr]

The two rear bungs need to be pushed through the holes so that their heads retain the box. Looks like yours might be just sitting on the bungs which will leave them sitting high.

 

[nicholsonj2252]

The two rear bungs need to be pushed through the holes so that their heads retain the box. Looks like yours might be just sitting on the bungs which will leave them sitting high.

OK , I’ll take a look


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[nicholsonj2252]

The two rear bungs need to be pushed through the holes so that their heads retain the box. Looks like yours might be just sitting on the bungs which will leave them sitting high.

Rear bungs now fully engaged ;-)

 

[B Murr]

And does the seat now fit?

 

[nicholsonj2252]

And does the seat now fit?

The seat fitted as soon as I reduced the height of the single bung that sits under the tool tray from 20mm to 10mm . The two rear bungs as you rightly spotted were not engaged fully which I have now corrected but the seat was only catching on the front not the rear so the rear bungs not being fully engaged I do not think was part of the problem with the seat not fitting

I would still like to know if you get a chance the height of your single bung that sits under the tool tray

 

[B Murr]

I'll have a look tomorrow. Watching Alice Roberts on BBC2 now examining origins of Stonehenge, with a glass of red and some mature cheddar on farmhouse bread, heaven.

 

[nicholsonj2252]

I'll have a look tomorrow. Watching Alice Roberts on BBC2 now examining origins of Stonehenge, with a glass of red and some mature cheddar on farmhouse bread, heaven.

Enjoy !

 

[kirby morgan]

The front bung fitted protrudes 22mm. At least thats on my R100gs pd.

 

[nicholsonj2252]

The front bung fitted protrudes 22mm. At least thats on my R100gs pd.

Which mine did also but that made the tray sit too high when fitted with the Motobatt battery


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[B Murr]

Bung is 14mm, box depth around 72mm and it looks like this. This photo taken with lid removed and camera angle such that its dead level with the subframe bars on top. Your box is definitely sitting higher, must be a bigger box.

 

[B Murr]

Part number for box just in case there are different versions.