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#1 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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XR650L: Subframe Reinforcment
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.
![]() ![]() ![]() 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. ![]() ![]() Spud ![]()
__________________
Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." ![]() 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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#2 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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It looks like triangulating the subframe is a good idea (and cheap insurance). It all but disappears from the side.
PVC is a good idea. It's cheap, easy to work with and light. ABS is a similar option, and it's already black.
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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#3 |
Join Date: May 2009
Location: Chickamauga, Ga.
Posts: 278
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+1 on the abs no painting needed. i have been wanting to replace my tool carrier with something better myself. i been thinking of making one big enough for my tools and spare cdi.
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my help may not be the best but it is free+-Seek ye first the kingdom of GOD |
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#4 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Thanks for the feedback, gentlemen.
![]() Spud ![]()
__________________
Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." ![]() 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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#5 |
Join Date: Oct 2009
Location: Alberta, Canada
Posts: 3,274
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Subframe reinforcement is always a good idea, manufacturers always seem to engineer the subframe attachments a little on the light side
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#6 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Thanks for the tip, Stew!
![]() ![]() ![]() http://www.agrisupply.com/manual-canister/c/1900088/ Spud ![]()
__________________
Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." ![]() 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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#7 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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I think this KTM LC4 tool box is just about the perfect size to place on my left subframe strut.
![]() http://www.dual-star.com/index2/Bran...4_tool_box.htm ![]() ![]() ![]() Does anyone know of other, similar tool boxes I might consider? Spud ![]()
__________________
Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." ![]() 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 |
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