Help with a Vario Top Box problem please

[ram678]

I had a small argument with a truck in Sofia last weekend - truck won when it hit the back of me! Top Box only suffered superficial external damage but the red rod that releases the box from the mount has become 2 parts. The part that goes to the catch that releases the mechanism and the squared lower section that goes down to the bottom of the box. I tried bending the 2 bits apart in the hope that I could slide the lower part back into the top part but I got to the point where I thought it might break. What happens if I take out the 2 cross head screws that look like the might hold the release mechanism (from the base plate) at the bottom of the case? What about the 2 smaller screws nearly flush with the side of the case? I'm stuck with a top box that wont remove from the base (mounting) plate at present. Any ideas gratefully received. Brian

 

[ram678]

Help with removing Vario To Box

No answers. Maybe I didn't put the problem clearly. I have a top box mounted on its mounting plate that I cannot remove from the bike because the red rod that releases it has seperated inside the box. I tried twisting the lower section with pliers but this seems to have become displaced from its proper seating as well. If I take out the screws at the bottom of the inside of the box will the release mechanism remain clamped to the mounting plate so I can lift the box off and sort it out? or will springs fly all over the place never to be replaced again? Not easy to take it to the BMW agent as I work in Kosovo, over 4 hours to the nearest in either Belgrade, Serbia or Thessaloniki, Greece. I am fairly handy with the spanners but would like to know what might happen before I start pulling it apart. Ideas/experience needed please. Brian

 

[freeloader]

No guarantee of a definitive answer here, but from a quick look at my vario topbox, you might be able to release the box from the mounting plate by removing the four screws at the hinge side of the case (two on each side). My guess is that this would release the two fixed plastic "hooks" on that side, and, HOPEFULLY, that should allow the box to come away from the mounting plate.

Otherwise, you might not have a choice about removing the two screws on the "catch" side, since there are no other fixings to remove on the bottom (outside) of the case. I'm saying this from the point of view of someone who hasn't done this, you understand, but I think it's what I would do. If I had more time I'd do it myself, but circumstances dictate against it. Sorry!

I wish you luck!

 

[freeloader]

Update...

1) If you remove the 4 screws on the inside of the base of the case, along the hinge side, the "hooks" which secure the case to the mounting plate will drop straight off - or they do on mine.

2) If you remove the two screws on the latch side of the case, the handle assembly should drop away, but there are 2 springs involved; one is a 1" long, 8mm dia, compression spring which is awkward to replace, and which will probably fly away unless you're careful. The other spring is hooked at both ends, is about the same size, and normally holds the steel loop of 4mm/5mm rod (which latches the case to the mounting plate) in place.

3) I didn't take any photographs, since as I haven't subscribed yet, I wouldn't be able to post them anyway.

I hope you can make enough sense of these posts to remove your case, especially since it's worth repeating that that little compression spring is a real sod to put back; I eventually held it in place with a cable tie, and managed to snip it off once the handle was back in position. Took me a while though!

 

[ram678]

Top Box - Job done nearly

Thanks Freeloader. Followed your advice and it all worked as you said it would. My only problem is - where does the spring with a loop at each end attach? one end goes over the release bar/latch, there is a clear grove in this but where does the other end fit? I'm afraid it just fell out when I removed the mechanism from the bottom of the box, so couldn't see its original fitment place. I expect I can work it our by trial and error eventually but as you said the other spring is not the easiest to get seated, so I don't want to be putting that one in and out too much!! But thanks very much it was a great help.
Brian

 

[freeloader]

You're welcome, Brian. As for the spring you mentioned, as you'll probably have worked out, it pulls the loop forward. One end goes where you deduced, and the other end goes into a small hole in (and here it gets hazy, sorry!) what looks like a slot, but appears to have a hole at the rear end of it, in a rectangular protrusion which sits roughly in the centre of the "arch" through which the metal loop protrudes through, where it locks into the mounting plate.

Sorry, that's about the best I can describe it. Not terribly clear, I know.

If the rectangular blob's missing, I suppose it may have been a casualty of your initial smack by the other vehicle. On my box, it doesn't look particularly fragile, but BMW plastic being BMW plastic , you never know.

If it is missing, I could dismantle it again (!) and take a photograph, and email it to you.

David

 

[ram678]

Vario Top Box

Dear Freeloader,

Your help and the trouble that you have gone to is really appreciated. You have done far more than I had hoped for already, so please don't go to the trouble of taking your top box apart again. From you last advice I am sure that I can finish the job off now. Incidentally, the red release rod, that had come apart into 2 pieces was put back together by undoing the 4 screw on the cantilever arms of the expanding system, once they were released the box could be expanded further than normal and the 2 pieces slotted into each other. Thanks again for your valuable advice.
Brian

 

[freeloader]

Happy to be of service!

Brian,

You're welcome, and I will have benefited too, if the same thing ever happens to me! From what you say about the rod, it sounds like the damage wasn't as bad as it might have been anyway, so that's good. However, if you haven't got that other spring replaced, and the box is otherwise okay to use straight away, the spring needs to be fitted for the box to mount securely to the mounting plate. Although it's probably obvious when you try to fit it...

David