Repair FJR 1300/A 2006 subframe / Επισκευή Υποπλαισίου

It all started a couple of months ago when we return from a short trip my wife and me. Actually it wasn’t even a full trip we just wanted to escape on a nearby resort about 110 km away from our base. When we returned home a noticed that the rear GIVI luggage was swinging up and down as it had no support. Immediately I removed the rear seat and noticed that on the sub frame and at the end of the tail where two cracks as well as the pillion rear handles which serve as tail reinforcement for the luggage weight.   

As you will noticed in the photos when I discover the price of the spares I have unsuccessful tried to glue it with Permatex “plastic steel” putty. The sub frame is pure aluminum and it didn’t last more than a week and without the rear luggage.

While searching over the internet I discovered that there are several FJR owners that had or have same problem globally. The solution which was offered was either welding the sub frame or replace it.

Further research found a shop in Holland that had used FJR spare parts (most probably from wrecked bikes) that had available sub frame.  Just to give you a hint the local Yamaha retailer replied that the original spare had a couple of months delivery and cost more than 700 Euro (800USD) while the used had  225 Euro (250 USD) price. The only spare could found used was the pillion rear handles which in Yamaha shop cost 300 Euro (350usd) and had 20 days delivery.

Without a much of a choice I have ordered both items respectively.

Once I received them and in view of another 300 Euro (350$) for any mechanic workshop installation payment I decided to do it on my own as I have seen other FJR owners did the same.

Following the spare parts catalog found quite easy to remove all the necessary bolts and removed the sub frame.

 I followed an American fellow that he advised not to remove the rear plastic and remove only the sub frame.

 Thereafter I proceed with frame installation

What it will puzzle you is the sub frame must pass under the hydraulic pump and over a steel plate which holds the pump from the left side and the electric plug from the right side. It is tricky but can be done with a lot of patience and some luck.

 

Thereafter all went swell and the FJR was ready in 60 minutes for a ride.

I would advise all fellow riders to reinforce the tail (relevant article you can find at FJR owners site) and keep luggage load to absolutely maker’s advice no matter how much your wife screams about her make up or the hair dryer.