Top Case Problem R1200RT

[Our Gee]

Hi all,

Help !!. Recently I had a solo trip to Scotland and as I didn't require a large luggage capacity I left the 49 Litre Top Case at home. However I did take some items strapped to the rear rack. To protect the paint I wrapped a good few turns of insulating tape around the rack at the locations where the top case securing mechanism locates.
When I returned I stupidly fitted the Top Case forgetting to remove the tape which meant that the "push down" handle was very stiff (no doubt due to the extra thickness caused by the tape). I did manage to lock the case in position but now after removing the tape and locking the top case in position the handle looks slightly crooked and does not fully sit into it's recess on one side. So it looks like I have bent something.
I have done a search for info about top case dis-assembly but can't find anything. If anyone has experience of this problem and can offer advice it's much appreciated.
Thanks.

 

[steadysteve]

Difficult to diagnose from a distance but I've disassembled a couple of these and the weak point seems to be the thin gauge metal that slides between the two plastic shells- it is easily distorted.. but that probably doesn't explain your crooked handle as it's fairly substantial and has solid hinge pins. Only thing I could suggest is the excess force on the pins may have strained the plastic that they mount into, causing the handle to twist.
The assembly with the locking lever comes off relatively easily but make sure you mark the ratchet teeth with paint to ensure you get them in the same position on re-assembly, otherwise the claws don't push out far enough (allowing the box to move about on the rack) or try to move too far out and put strain on the mechanism..

 

[Our Gee]

Many thanks for the reply and useful info Steve. If I do need to have a look under the black plastic case liner is it just a case of removing all of the Torx Screws or is it also necessary to remove the pop rivets.
Thanks again.

 

[steadysteve]

You might not have to dismantle it completely, from what you have said, because that handle mech comes off separately but if you do take the liner out it's just the torx screws- don't miss the one under the handles and there are also two 8mm nuts under the handles which are a bit fiddly, especially when it comes to putting them back on.
Also remove the lid before you start, to stop the whole lot falling backwards on the bench.

You will also need lots of deep breaths, a good supply of expletives and lots of patience.
Shout if you get stuck...