Frame cracks MKII - must read

[jasonm.]

I have had this 87' royale for 25 years. Reading this could save you problems. The chrome rack assembly that the trunk sits on, mounts to the frame at 4 points. These 4 frame points can crack or BREAK. I found the reason being the factory simply does not exactly make these racks to match up every time. They use air wrenches during assy. And things are forced to fit. And even if you removed the trunk and rack for servicing the air compressor...you thought this was normal...okay. IT'S NOT OKAY. You are placing twisting forces to the steel frame mounts which hold the rack assembly. And if you typically ride with a loaded trunk, stresses increase. And if you also have an OEM trunk light bar like I did with 16 lights(8 is standard)..that's an extra 7 pounds hanging out there. The trunk with OEM rack weighs close to 30# then is rated for another 20#. That's 50# bouncing and potentially adding to the stresses. The most common cracking is the front "L" mounts where they make a 90 degree bend. I was lucky and had a low mileage parts bike and swapped rear frames and chrome racks. BUT the rack from my low mileage parts bike also did not line up properly. And it also had a short stress crack at the 90 degree bend on right tab, which a welded. Which clearly was due to this misalignment. FYI- to mount the chrome rack you must FIRST install the two bolts closest to the seat and tighten them completey. Then see if the other two rear holes line up. High probability, they do not line up. You can try loosening the two fron bolt to get the rear 2 close as possible. But you only have approx. 2 mm you can move it. BUT you likely will need a rasp file to widen the rear holes. Or possibly with 2 front bolts tightened, need to torch the front mounts on the chrome rack red hot and bend the rack into place vertically. Bottom line DO NOT put all 4 bolts in at the same time. Do front completely tight w/o the rears installed, then rear. When perfectly aligned...The rears should go in without ANY resistance by touching the chrome rack. Not sure if MKI is similar. Probably is. Remove seat and plastic black back panels near tail light..Look at your frame NOW. I hope to post pictures...it was bad. Look carefully and let me know if you found cracks. MAYBE Use a magnafying glass and look at the paint. Lastly...I ride solo and only need the trunk to safely lock up the helmet. For now the trunk is off and will stay off till a long trip. And the bike handles WOW better. Always a great handling bike, now only better. Handles just like my friend's FJR13. Maybe the MK1 guys w/removable trunk have done this and already know.

Edited July 14, 2014 by jasonm.