Advice needed fitting top box support frame. 2005

[PaddyM]

Ok guys, I have just recently purchased a top box for my 05 r1200gs. The box came with the base plate and the mounting frame. Now I have noticed that the plastic section above my tail light is fouling the metal frame from sitting correctly into position and also the stock bolts are not long enough.
Just wondering if anyone else has had this problem. Im guessing it may be a case of trimming the plastic shroud and get longer bolts. Hard to fully explain so hope the pictures explain a bit better.

 

[Greenman14]

You do need to fit the support frame. I've followed a GS with a top box and no support frame and the box was all over the place.

 

[PaddyM]

I will be fitting it Greenman. Just need to find out if I need to start trimming plastic for it to fit.

 

[Blackal]

You need to trim the plastic at the back to get the support bosses in.

 

[PaddyM]

Ok,I'll mark it out and cut it with a dremmel or similar. You don't happen to know where I could get longer bolts for securing it ?

 

[Blackal]

Sorry, cant remember where mine came from.

Google search for the right length?

 

[PaddyM]

Thanks for the advice

 

[UturnTony]

You need the cut outs to fit it, iirc later bikes had them as standard.

 

[Steptoe]

I've lost count the number of bikes I've had in with those support plate bolts broken. So use quality bolts and some anti seize, makes the job of removing the broken stud much easier

 

[PaddyM]

I'm struggling to find the size of the bolt required.

 

[Bendy toy]

Try an M6 or even M8 nut on the original screws. Then order high tensile to suit. As Steptoe says, use a decent anti seize paste on the threads.

 

[Bobbin-Man]

PaddyM, I'm pretty sure the bolts you need will be around M6 x 40mm. I think I'll have a couple spare that size in stainless, pm me your details and I'll pop them in the post.

Stu.

 

[Bendy toy]

I would go for galvanised ferrous or even high tensile screws. Stainless tends to shake loose and creeps under load.

 

[Greenman14]

I have a spare seat base you can have if you'd like to keep yours original. Mine is accident damaged and a pair of the side hooks thins are broken but the important pannier fittings are fine. PM me if you're interested.

And Bendy's right, the bolts do tend to loosen over time, something to check when you're washing, checking tyres etc.

 

[Blackal]

I would go for galvanised ferrous or even high tensile screws. Stainless tends to shake loose and creeps under load.

I’m inclined to use good quality stainless, as for the most part the cantilevered load is pushing the boss onto the frame. I had the Vario box fitted to a GSA for 4yrs, and you would think it was filled with house-bricks on holidays - so the momentum pulling on the bolts (potholes etc) could be quite severe - no issues on mine (with SS bolts).

In summary - I would prefer a tough metal to a high tensile.

 

[Bendy toy]

Stainless is good in shear but it shakes loose all too easily.

This setup will shake vertically, putting a lot of shear load on those bolts. M6 of any type is really not enough to cope. See if you can get a sleeve anchor to fit the frame tube and use a larger bolt. IIRC the existing end plugs are in effect sleeve anchors but I may well be wrong.