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#831470 - 05/03/13 07:13 PM how to disassemble 49L top box? (Tutorial in the answers)  
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rottyjohn Offline
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rottyjohn  Offline
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Hello everyone... anyone have any instructions on how to disassemble the bottom half of the topbox? The slidling latch just to the left of the main handle is coming out of the track. Causing latch to bind up. I removed all the screws but it would not come out. Do I have to drill out 2 rivots out to get to back side of latch and remove liner pan? Thanks sure would appreciate any ideas or pictures.

John

Last edited by Kathy R; 08/27/14 02:51 PM.
#831528 - 05/04/13 10:09 AM Re: how to disassemble 49L top box? [Re: rottyjohn]  
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WestyLancs Offline
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WestyLancs  Offline
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Bolton, England
Hi John,
When I did similar with the side cases on my RT I used the 'exploded' diagram on A&S Microfiche site.
Helped me visualise which fasteners held what in place.

Looks like they do a similar diagram for the 49L, but don't know if it'll help you.
It doesn't seem to show rivets in the parts list.

A&S parts list 49L box


Ian

2006 R1200 RT
2014 Suzuki Burgman Executive 'maxi' scooter
#832422 - 05/11/13 02:00 AM Re: how to disassemble 49L top box? [Re: rottyjohn]  
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DiggerJim Offline
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Simsbury, CT
no drilling needed. There are some screws under the handle that have to come out to free up the inner liner. Of course you can't get a screw driver (actually I think it's torx) in there - you need to use a short bit that you stick in the screw head and then use a 1/4" wrench to turn it. A bit fiddly but doable with patience. Getting it back together is trickier as you've got to get the lower sliding tracks right or it won't grab the rear deck of the bike mount.


----------
Jim
2007 R1200RT Bairritz Blue - hexhead 1200
2000 R1200C Ice (Frost) Blue - oilhead 1200
1996 CBR600 Joe Camel Special - hooligan bike
1986 KZ650 Green - classic old school
IBA #35635
#844492 - 07/31/13 09:39 PM Re: how to disassemble 49L top box? [Re: rottyjohn]  
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sparra Offline
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Queensland, Australia
Hey John,
Did you get this resolved?
I have an issue with the latches on the left not sliding at all, and removing all screws from the inner skin, and the two from the handle, as advised in previous post, still didn't allow access/removal.

#844523 - 08/01/13 12:01 AM Re: how to disassemble 49L top box? [Re: sparra]  
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Brian Louw Offline
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Brian Louw  Offline
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Arroyo Grande, CA
There are two T25 screws and two 8mm nuts under the handle that need to be removed. Not much room to work in there, but you can do it with an 8mm offset ring wrench.
Parts numbers 6 and 11 in the exploded drawing.

Last edited by Brian Louw; 08/01/13 12:04 AM.

Brian Louw

'13 K1600GT
'11 R1200GSA
#859674 - 11/02/13 12:58 PM Re: how to disassemble 49L top box? [Re: rottyjohn]  
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Remco Offline
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Perhaps this may help. I found myself unable to lock the box and filing down the engaging plates on the lid didnt help - so I took it apart. The above information, notably of Brian Louw was most helpful. I would add the following to help anyone contemplating disassembling the lower half of the 49L.
1. Remove the lid (four screws)
2. remove all screws except the two under the handle.
3. remove the nuts under the handle
4. pull the unit apart (if it doesnt, you may have skipped a screw on the side.
You may need to remove the screws under the handle at this point depending on what you are doing.

Reassembling.
Slide the inner lining so the external engaging feet slide through the openings at the bottom (ie away from you with handles close to you)
1. Make sure the two pairs of engagement pins (these are what the lid engages) are set at min (ie. the left and right close to handle and the pair above the handle close together). IMPORTANT!
2. Make sure the traveler on the left (handle towards you) is engaged in the track.
3, Make sure the running rail is BEHIND the lip (this was the reason I had to disassemble the unit). To explain, there are two openings left and right of the handle where the lid engages and each has a plastic tab where the rail must be behind.
4. Make sure the rail is engaged in the locking mechanism.
5. Fasten handles both set to open (use key).
6 Insert screws around bottom (care, dont confuse them for the bolts needed for sides etc.)
7. Fasten lid with four screws into the hinges.
I hope this helps. It really is tricky and needs a video to make clear.

#859677 - 11/02/13 01:26 PM Re: how to disassemble 49L top box? [Re: DiggerJim]  
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barnonline Offline
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Denmark
Thank you, just the information I needed. I did see the torx screws, but for some reason I didn't the 8mm nuts.

My recently aqurired k1200gt fell over in a storm. It appears to be a know issue with mc the sidestand, the mc MUST be in gear to prevent it from rolling forward and tipping over.

Afterwards I could not close and lock the lid properly.

After a complete disassembly I found that the metal prong on the lid was ever so slightly bend inwards. That meant that the locking pins in the lower part of the topbox, could not engage correctly.

After a slight bending outwards of the prongs, it closed and lock again.

#899985 - 08/18/14 06:23 AM Re: how to disassemble 49L top box? [Re: rottyjohn]  
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Vini Offline
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Digging this up to try and help a bit more on the subject.

Yesterday I wanted to clean and lubricate my top case but ended up not being able to lock it after a failed attempt to take it apart. So following Remco's instructions I managed to take it to bits and though I could add to it with some pics.. so here you go. It is a mix of his instructions + my notes + pics:













All the bits

#900088 - 08/18/14 10:25 PM Re: how to disassemble 49L top box? [Re: Vini]  
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lawnchairboy Offline
Snuggie Jesus
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Traffic hell, VA
http://images.wikia.com/uncyclopedia/images/archive/8/87/20080307020656!Mousetrap.jpg


06 R12RT (for sale) 11 R12GS (for sale) 11 KTM990 ADV

The focus is sharp in the city.
#900103 - 08/19/14 12:37 AM Re: how to disassemble 49L top box? [Re: lawnchairboy]  
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lkraus Offline
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Central Ohio
Originally Posted By: lawnchairboy
http://images.wikia.com/uncyclopedia/images/archive/8/87/20080307020656!Mousetrap.jpg




Fixed

Vini, thanks for the pics. these will help answer a lot of questions.

Last edited by lkraus; 08/19/14 12:39 AM.

Larry
2006 R1200RT
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