Cracked Subframe

Ignacio · Apr 6, 2007

I had talked about my cracked subframe and decided to pull it off instead of welding it in place.

Here's a full write-up of the disassembly process for those interested in seeing what it looks like to take the *** off of an FJR.

It took about 2 hours to do including taking pictures and some notes.....not as bad I had feared. One doesn't have to remove the airbox or ABS unit. Hopefully, reassembly will go as smoothly.

I'm hoping the repaired and improved subframe will be done this weekend. More pics then.

twowheelnut · Apr 6, 2007

Very nice write-up. Alas, not quite complete without this.

Looking forward to the next episode.

keithaba · Apr 6, 2007

Excellent writeup! Just in time for me too. I'm glad it sounds easier than I thought it would be.

Are you going to re-apply loctite to those 4 screws before re-assembling? Or are you just going to torque it down to the proper specification? (I'm sure it's in the service manual somewhere).

Ignacio · Apr 6, 2007

keithaba said:
Excellent writeup! Just in time for me too. I'm glad it sounds easier than I thought it would be.
Are you going to re-apply loctite to those 4 screws before re-assembling? Or are you just going to torque it down to the proper specification? (I'm sure it's in the service manual somewhere).

Thanks and you're welcome! I hope it helps.

I'll definitely be checking the service manual on reassembly for torques of these bolts and it will show about Loctite.....which I'm sure will show as needing Loctite. I don't have the green stuff so will probably have to buy a bottle. Unlike uber-Arnold the Japanese assembler that gets over-gnarly on other fasteners....I can see why they want these particular bolts fastened securely.

Grumpy · Apr 6, 2007

How in the world did you find this in the first place?

jim

Scab · Apr 6, 2007

And just how big are the women you ride on the back of this thing?

raclow · Apr 6, 2007

I'm wondering if your Pelican case can do this, what keeps a Top Case from doing the same? I have a Top Case and now I'm going out to inspect my bike for these cracks.

How much weight do you think you carry on a regular basis in that case??

I'm thinking, Top Case with cargo plus Pillion leaning back on the case is not good. Yamaha had to believe this could be the case with the bike and loading parameters.

This may be another situation for Yamaha to have a re-call on this portion of the sub-frame.

Is there a weight limit in the owners manual for the Top Case?? I find a 7lb weight limit for the storage area under the seat.

Can anyone help with this??

Sorry this has happened to you and the others....if it becomes a more common thing, I go back to Yamaha being responsible for this flaw in design.

Bounce · Apr 6, 2007

FYI: Top cases on Wings are rated at something like 20 lbs or less.

And those were designed with the top case from the factory.

wpbfjr · Apr 6, 2007

raclow said:
I'm wondering if your Pelican case can do this, what keeps a Top Case from doing the same? I have a Top Case and now I'm going out to inspect my bike for these cracks.
How much weight do you think you carry on a regular basis in that case??

i have a similar pelican setup...

matt will weigh in, but i see no recall/flaw potential since we took off the factory rack...

the factory rack has 5 mounting points, vs. the 3 for the pelican case...

the 2 mounting points under the pillion seat provide what i think is called 'cataliver' support, to off-set the flex of the yammi topbox, and any weight transmitted thru the passenger backrest...

i'm not an engineer, just how i think i understand it to be...

dana

Ignacio · Apr 6, 2007

wpbfjr said:
raclow said:

I'm wondering if your Pelican case can do this, what keeps a Top Case from doing the same? I have a Top Case and now I'm going out to inspect my bike for these cracks.
How much weight do you think you carry on a regular basis in that case??

Click to expand...

i have a similar pelican setup...

matt will weigh in, but i see no recall/flaw potential since we took off the factory rack...

the factory rack has 5 mounting points, vs. the 3 for the pelican case...

the 2 mounting points under the pillion seat provide what i think is called 'cataliver' support, to off-set the flex of the yammi topbox, and any weight transmitted thru the passenger backrest...

i'm not an engineer, just how i think i understand it to be...

dana

Exactly right. The Pelican case design I used is because I can't use a stock Yamaha or Givi case because of my fuel cell. As I said in the previous threads I'm going to redesign my mounting system. No reason Yamaha should recall anything....it's not a design flaw if used as designed. People with top and Givis shouldn't worry.

I'm clearly using it beyond it's design limits.

My next thread will have pictures of a repaired, reinforced subframe, AND modified mount for use with this unusual arrangement.

The write-up is intended for people to just see what a subframe looks like and for those folks that might have or consider a Pelican.

....either that I have an unusual affection for really big chicks on the back of my bike :blink:

Rickster · Apr 6, 2007

Ignacio said:
....either that I have an unusual infection from really big chicks on the back of my bike :dribble:

There Iggy, I fixed it for you!

that would explain the broken crack and all that 'subframe' issues if that's what you kids call it these days.

mech 1 twa · Apr 6, 2007

Mine cracked in exact spot, except on the left side. 05 also.

Bike was still under Warr. dealer replaced it.

I overloaded at least once on a trip. Don't know when it cracked for sure.

I was wiring some new lights and found it.

I suspect there are a few more out there.

Good write up.

raclow · Apr 7, 2007

Ignacio said:
wpbfjr said:

raclow said:

I'm wondering if your Pelican case can do this, what keeps a Top Case from doing the same? I have a Top Case and now I'm going out to inspect my bike for these cracks.
How much weight do you think you carry on a regular basis in that case??

Click to expand...

i have a similar pelican setup...

matt will weigh in, but i see no recall/flaw potential since we took off the factory rack...

the factory rack has 5 mounting points, vs. the 3 for the pelican case...

the 2 mounting points under the pillion seat provide what i think is called 'cataliver' support, to off-set the flex of the yammi topbox, and any weight transmitted thru the passenger backrest...

i'm not an engineer, just how i think i understand it to be...

dana

Click to expand...

Exactly right. The Pelican case design I used is because I can't use a stock Yamaha or Givi case because of my fuel cell. As I said in the previous threads I'm going to redesign my mounting system. No reason Yamaha should recall anything....it's not a design flaw if used as designed. People with top and Givis shouldn't worry.

I'm clearly using it beyond it's design limits.

My next thread will have pictures of a repaired AND reinforced subframe and modified mount for use with this unusual arrangement.

The write-up is intended for people to just see what a subframe looks like and for those folks that might have or consider a Pelican.

....either that I have an unusual affection for really big chicks on the back of my bike :blink:

Thanks for the response. I haven't had the chance to check my sub-frame as of yet....but I will.

Will get back to you as I find out my findings.

BrunDog · Apr 7, 2007

Linky no worky Matt!

-BD

zzzzip · Apr 7, 2007

raclow said:
I'm wondering if your Pelican case can do this, what keeps a Top Case from doing the same? I have a Top Case and now I'm going out to inspect my bike for these cracks.
How much weight do you think you carry on a regular basis in that case??

I'm thinking, Top Case with cargo plus Pillion leaning back on the case is not good. Yamaha had to believe this could be the case with the bike and loading parameters.

This may be another situation for Yamaha to have a re-call on this portion of the sub-frame.

Is there a weight limit in the owners manual for the Top Case?? I find a 7lb weight limit for the storage area under the seat.

Can anyone help with this??

Sorry this has happened to you and the others....if it becomes a more common thing, I go back to Yamaha being responsible for this flaw in design.

Max weight for the top case should be posted in the case on a sticker. No longer have my '04 with TC so can't tell you #s. Should all so be in the owner's manual.

B)

Ignacio · Apr 7, 2007

BrunDog said:
Linky no worky Matt!
-BD

Sorry. I had fixed a glitch in the way dates were generated and hosed the "permalink". It should be fixed in the original post now. General link to my IBR blog is here as well.

raclow · Apr 7, 2007

zzzzip said:
Max weight for the top case should be posted in the case on a sticker. No longer have my '04 with TC so can't tell you #s. Should all so be in the owner's manual. B)

I found the weights and would like to pass along.

Top Case: 11 Pounds/Cargo

Side Cases: 22 Pounds/Cargo each

Owners Manual for both says do not use side cases or top case in conjunction with one another.

None of us here are going to that

Ignacio · Apr 7, 2007

raclow said:
zzzzip said:

Max weight for the top case should be posted in the case on a sticker. No longer have my '04 with TC so can't tell you #s. Should all so be in the owner's manual. B)

Click to expand...

I found the weights and would like to pass along.

Top Case: 11 Pounds/Cargo

Side Cases: 22 Pounds/Cargo each

Owners Manual for both says do not use side cases or top case in conjunction with one another.

None of us here are going to that

Exactly. They covered their butts. They certainly peform to that minimum and I'm sure I have more than 11 pounds in my Pelican case. Hopefully, with the new and improved welds I'll be able to carry that without any future cracks

wpbfjr · Apr 7, 2007

Ignacio said:
Hopefully, with the new and improved welds I'll be able to carry that without any future cracks

so, are you intending to acheive support solely via reinforcing welds to the subframe and its mounting points, or will you also include some sort of cantilever arms to the factory mounts under the pillon seat?

dana

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