2006 Vario Topbox problem - self-detachment

Mick-B

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I know it's been covered before but, last Friday evening rush-hour, A12 Newbury Park (East London) flowing well at 40-50mph (but very busy) when I heard what sounded like a box tumbling, rapidly followed by the sound of metal sliding on tarmac, and much hooting of vehicle horns...

The more astute will have guessed that the Vario topbox on my 74,000m 2006 GS had decided that was the moment to self-eject into the path of following traffic.

Fortunately (for me, for my luggage, numerous following drivers / riders) I was in the nearside lane rather than lanes two or three, the box stayed intact and slid into the nearside gutter whereupon a pedestrian kindly picked it up... it was piddling with rain and clearly the whole episode could have ended oh so very badly.

As it is, the pedestrian handed me the box (he seemed happy not to have to carry it any further; he indicated he had decided to take it to the nearest Police Station :)), and the topbox has suffered no more than the disappearance of the upper backrest and a significantly scuffed aluminium top panel.

Yes, the pathetic layer of plastic that holds the metal securing hasp in place had split. I've now added a piece of 1.5mm galvanised steel plate held in place with some 6mm bolts and washers which seems to have made the fitment rather more secure. OK, in factory original finish the topbox has lasted 74,000m albeit on tarmac rather than off-road but why couldn't the bods at BMW have come up with a more robust design?

Meantime, if you have a Vario topbox, it might save you a similar experience by checking for cracking and even if there is none, do consider fitting a reinforcing plate. (I wish that I had :mad:)
 
Thanks for the info big yin. I just checked mine and guess what? It's cracked right in the spot you explained. Time to look out a wee aluminium strip to reinforce it.
 
The box Bryn - it was an issue with early varios. Mine had a crack and was replaced with an updated one. 10 years on and heavy usage and it's still going strong.

Andred
 
The box Bryn - it was an issue with early varios. Mine had a crack and was replaced with an updated one. 10 years on and heavy usage and it's still going strong.

Andred

Got mine second hand so don't know its age.... Can't see any cracks though :thumb2
 
Have 2004 with original vario top box and am not sure (1) which part of the top box, or is it the adapter plate, that can crack causing the box to self-detach (2) what is the actual solution as reference is made to: an upgrade or fitting 2 x 6mm bolts or fitting metal reinforcement strip. Wifey has habit of leaning back against top box so am concerned self-detachment of top box will be closely followed by self-detachment of the wife!! Also anyone done an improvement on vario topbox backrest to enhance pillion comfort on long runs?? Any photos would be good ~ top boxes not readers wives.
 
I've checked my 2005 topbox and this also has a split on the underside plastic cover of the securing catch.

Time to either modify or replace, I reckon.

I'll add a photo of the method that is used on a more recent version of the vario topbox. You can see that a couple of security enhancements are added - by a simple bolt in the recess near the catch; and a plate (across the top edge of the recess).

ImageUploadedByTapatalk1406620710.838435.jpg
 
http://www.advrider.com/forums/showthread.php?t=643013

The above thread from advrider has some useful stuff on securing top boxes. There's about 10 pages in all so you'll have to scan through other stuff to find it.

Yep, some excellent stuff interspersed with some inevitable drivel... So, BMW's "Enduro" kit simply comprises some bolts to secure the topbox to the carrier plate (at a premium price for the correctly sized spacers and o-rings) but the option of clevis pins and R-clips would work nicely if the pins were bonded in some way to the topcase to prevent water ingress.

Better still, cut a thread on the top of the clevis pins so they can be both correctly adjusted to length and secured and weather-sealed (with a couple of slim nuts and washers) to the underside of the topcase - thus the box still removes quickly and easily as required but cannot detach whilst the R-clips are in place.
 
As Browny's picture shows, it's on the rear underside of the topbox, between the latch release lever and the recess where the latch protrudes. The thin plastic casing (about 40mm wide by maybe 1mm thick - approx) is supposed to keep the latch in place, parallel to the base of the topbox. When the casing cracks, the latch can be forced away from the topbox and then the topbox falls off....

The bolt in the recess is apparently a locating pin to stop the box moving horizontally on the mounting plate and thus allowing the latch to become disengaged from the mounting plate.
 
Well...famous last words.... looked last week and no crack in the plastic ... looked today and there is one :blast

So thanks to this thread.... slice of 2mm ally plate across the affected area, bolted through with 4mm stainless bolts... that should strengthen the bugger :beerjug:
 

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