XR650L: Subframe Reinforcment

[SpudRider]

The subframe on the Honda XR650L has been known to fail under heavy loads. :( I frequently pack my J.C. Whitney Travel Trunk with a hefty load of groceries. I also plan to take short trips with my XR650L, and I would prefer to use the J.C. Whitney Travel Trunk as my luggage. Therefore, I decided I should reinforce the subframe of my XR650L. Since I removed the battery box when I performed my Shorai battery relocation, I decided to bolt a ¼-inch thick, steel bar between the two supports that previously held the frame for the battery box.



For the subframe support on the muffler side, my good friend Andy welded a short piece of steel bar at an angle to a longer piece of steel bar. I removed the rear fender brace, and mounted the rear of this bar with the bolt that previously held the fender brace. The bottom of the air box has a thick tab which is bolted to the bike's frame. I drilled a hole through this lower, air box support, and mounted the front of this subframe brace with a bolt through the air box tab, and the frame gusset which supports both the air box, and the front of the muffler.



Here is a photograph from the rear of my bike, showing the clearance between the subframe struts and the rear tire.



Here is a photograph of the right side of my bike, after the installation of the subframe struts. The front mounting bolt for the right side strut is located within the green circle in this photo.



Here is a photograph of the left side of my bike, after the installation of the subframe struts.



I have a 2-inch space between the outside of the left strut, and my XR600R side plastic. I would like to mount a tool tube/box to the outside of this strut, and remove the factory tool bag. With the stock tool bag removed, I can install a new, ManRacks RotoPax rack which mounts closer to the saddle, reducing the leverage the loaded rack exerts on the subframe. I reckon I can mount a piece of PVC pipe with a 2-inch outside diameter to serve as the new tool tube. However, I would appreciate receiving other suggestions for creating my new toolbox.

Spud