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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => The Motobrick Workshop => Topic started by: frankenduck on January 17, 2013, 11:30:57 AM

Title: BMW 22L Top Case: Hinge Stop Repair
Post by: frankenduck on January 17, 2013, 11:30:57 AM

The hinge stop that keeps the 22L top case from opening more than 90 degrees is made from some rather flimsy stamped steel that can, after repeated use, eventually bend and allow the top case to flop all of the way open.  It's easy to repair this with some 1/8" x 1" steel or aluminum bar stock from the hardware store. (In this case I used aluminum because it's what I had on hand.)

(You can buy a new one from the dealer for $15 (part 46542300439) but it will be just as flimsy as the original.)

STEP 1: Push the dowel out of the pin that holds the strap to the top of the case and remove the pin.

(http://i1221.photobucket.com/albums/dd470/Motobrick/luggage/22l_hinge_repair_1.jpg)

STEP 2: Turn the other end of the strap 90 degrees and remove it.

(http://i1221.photobucket.com/albums/dd470/Motobrick/luggage/22l_hinge_repair_2.jpg)

STEP 3: Cut a strip of the bar stock about 4" in length and put a bend in it.

(http://i1221.photobucket.com/albums/dd470/Motobrick/luggage/22l_hinge_repair_3.jpg)

STEP 4: Insert it into the channel behind the old hinge stop.

(http://i1221.photobucket.com/albums/dd470/Motobrick/luggage/22l_hinge_repair_4.jpg)

STEP 5: Reinstall the strap and voila! Hinge stop repaired.

(http://i1221.photobucket.com/albums/dd470/Motobrick/luggage/22l_hinge_repair_5.jpg)

Title: Re: BMW 22L Top Case: Hinge Stop Repair
Post by: Opus on January 17, 2013, 12:22:44 PM

Morning Duck !
Nice fix.
Maybe doing it before it breaks would be a good idea?
Also add a dab or two of epoxy to keep them together? (Less chance of Rattling?)

Just thinking out loud again....

Title: Re: BMW 22L Top Case: Hinge Stop Repair
Post by: frankenduck on January 17, 2013, 01:53:25 PM

Good idea. Reinforcing it before it bends would probably be a good preemptive strike.

BTW, next time I'm at the hardware store I'll probably pick up some steel to replace it since it'll be stronger.  I just made this out of aluminum because it's what i had on hand.

Title: Re: BMW 22L Top Case: Hinge Stop Repair
Post by: Opus on January 17, 2013, 03:37:25 PM

I see no problem using the aluminum. It is light and it should hold well as long as the top does not come open while you are doing 100 MPH!  :giggles
But I think the hold strap would break before the mount would.....

Going to add this to my list of "To Do's"...

Thanks for the idea!!!!!

Title: Re: BMW 22L Top Case: Hinge Stop Repair
Post by: Chaos on January 17, 2013, 05:51:41 PM

My problem was the coat-hanger wire latch setup.  Kept coming unlatched with all the flex in the box.  I finally reversed the hinge to the front and put a clasp lock on the back.  Never liked how the lid could catch the wind if it accidentally opened.  Been happy with the fix for the last 20 years.....

Title: Re: BMW 22L Top Case: Hinge Stop Repair
Post by: frankenduck on January 17, 2013, 05:55:27 PM

The key to getting the latch to work is experimentally tweaking the "coat hanger" to find what position works best.  Then smack the top case above the lock and make sure that the lock cylinder has popped all of the way out.

But yes, it IS a weird latch design.