Broken rear luggage handle. - BMW Luxury Touring Community
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post #1 of 27 Old May 21st, 2015, 7:33 pm Thread Starter
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Broken rear luggage handle.

Hi guys.

Have a 1999 K1200LT.

Recently the small upper left hand corner of the black rear luggage handle broke off.

That of course make impossible to open the case.

I removed the case and used layers of Crazy Glue to glue it back together.

Of course I could not remove the entire handle mechanism (which would've made things easier) since it is riveted to the case.

After I let the glue dry for at least 24 hrs, I put a layer of duct tape then a layer of Metal tape to give it strength. It seems to work just fine.

I re-installed the case on the bike. That day I carried a tape deck in the case and I guess it stressed the handle which broke again in the same place.

I guess I can glue it back again.

Any advice on what to do, should I use something else besides Crazy Glue that maybe stronger?

And what is the cost to replace the handle? I don't/can't spend a lot of money on this so the cheaper the better.

And is there an easy way to remove these rivets if I want to replace the handle or to make it easier to do the repairs ?

I am in San Jose, California if there is someone close to my area who have experience in this and wants to help me.

Thank you all,
AJ
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post #2 of 27 Old May 21st, 2015, 8:05 pm
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Re: Broken rear luggage handle.

There is a member here that has machined a "fix-it-before-it breaks" kit as well as new billet latch handle. Find it here.

John
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post #3 of 27 Old May 21st, 2015, 9:46 pm
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Re: Broken rear luggage handle.

If you are talking about the latch handle on the top rear case then the best option is to replace the latch with the replacement latch that jzeiler links to. Mine broke on my 2002 and the replacement latch definitely fixed the issue plus it came with all the needed hardware and instructions. There were some other methods people used in the hall of wisdom that you might still find but the best method is just to replace the latch.
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post #4 of 27 Old May 21st, 2015, 11:25 pm
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Re: Broken rear luggage handle.

I agree with John. That company makes two versions - Fix-it-Before-it-Breaks; and Fix-it-After-it-Breaks. I installed the Before version on mine. Sounds like you need the After version. It's a nice kit, but you would need to remove the topcase again to install it, unless you like to work upside down and have good eyes. Good luck!

Dave Beck
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post #5 of 27 Old May 22nd, 2015, 3:02 am Thread Starter
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Re: Broken rear luggage handle.

Thank you all for your replies.

Perhaps I am crazy but almost $400 is a lot of money for a handle. It is a lot of money to me at least.

Is there any other alternative?

I am curious to know about this Fix it before it breaks kit....where is the link to that please?

Also is there a way to glue mine back together so that it would hold?

I simply can't afford to spend $400 on a handle right now. That is not an option at this point.

Thank you.
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post #6 of 27 Old May 22nd, 2015, 3:29 am Thread Starter
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Re: Broken rear luggage handle.

Quote:
Originally Posted by BMW_forever View Post
Thank you all for your replies.

Perhaps I am crazy but almost $400 is a lot of money for a handle. It is a lot of money to me at least.

Is there any other alternative?

I am curious to know about this Fix it before it breaks kit....where is the link to that please?

Also is there a way to glue mine back together so that it would hold?

I simply can't afford to spend $400 on a handle right now. That is not an option at this point.

Thank you.

I found the Before kit....wish I've known about this before the damn thing broke...that is a more reasonable price than the $400 price for the After kit.
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post #7 of 27 Old May 22nd, 2015, 6:16 am
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Re: Broken rear luggage handle.

When mine broke about 4 years ago I found some post's by members who had repaired their latches with jbweld and metal angles that they had pop riveted to the existing latch after it was disassembled. If you check around on the forum you might still find those post's. I will admit I tried to repair mine and couldn't do it, so I just saved up and ordered the replacement latch. You might just have to use a bungee strap to hold it closed for now. Good luck.

Last edited by Diolach; May 22nd, 2015 at 6:16 am. Reason: misspelled word
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post #8 of 27 Old May 22nd, 2015, 1:31 pm
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Re: Broken rear luggage handle.

been meaning to do the before it breaks kit for over a year. Too late. I swear I was always gentle with it to. Sucks but too late, it has happened and broken. $375 is a good chunk of change to me too but unless you are friends with a killer machinist, save your pennies.

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post #9 of 27 Old May 22nd, 2015, 6:02 pm
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Re: Broken rear luggage handle.

the side that is broken,, glue the broken piece back on and repaint. Remove the latch pin pin from the case on the broken side, it will still lock using the non broken pin and relieve the pressure on the handle. My mate has had his like the for the past 10 years, I replaced mine yes it is expensive but you will never have the problem again.
Cheers

Regards Linton
From the land of Kangaroo's and Koalas
and no koalas are not Bears



2002 K1200LT
2010 Suzuki GSX 1250FA (the Wifes)
2004 Cub Kamparoo Sprint
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post #10 of 27 Old May 26th, 2015, 3:42 am Thread Starter
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Re: Broken rear luggage handle.

Can you explain more about removing the Pin please?

I assume that does not require removing the rivets (where the handle is riveted to the case) ?

The way it is laid out, it is not the easiest thing to work on or to access for repairs.
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post #11 of 27 Old May 26th, 2015, 4:48 am
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Re: Broken rear luggage handle.

open the trunk the latch pins are in the top half, the side that is broken on the handle remove the little "C" clip and slide the pin out and leave safe somewhere for future installation and always push down on the lid when you open and close it, this is not a fix but relieves the pressure. it will still function as before

Regards Linton
From the land of Kangaroo's and Koalas
and no koalas are not Bears



2002 K1200LT
2010 Suzuki GSX 1250FA (the Wifes)
2004 Cub Kamparoo Sprint
My Toys
1976 Datsun 260Z
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post #12 of 27 Old May 26th, 2015, 8:29 pm Thread Starter
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Re: Broken rear luggage handle.

Quote:
Originally Posted by Axle View Post
open the trunk the latch pins are in the top half, the side that is broken on the handle remove the little "C" clip and slide the pin out and leave safe somewhere for future installation and always push down on the lid when you open and close it, this is not a fix but relieves the pressure. it will still function as before
Remove the pin that is under the handle and held by 2 C clips?

That pin does not come out unless the entire handle mechanism is removed which involves removing the rivets holding it to the lower lid.
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post #13 of 27 Old May 26th, 2015, 8:43 pm
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Re: Broken rear luggage handle.

Quote:
Originally Posted by BMW_forever View Post
Remove the pin that is under the handle and held by 2 C clips?

That pin does not come out unless the entire handle mechanism is removed which involves removing the rivets holding it to the lower lid.
He is referring to the away inside the trunk - remove the liner to see

Gary
2018 R1200RT
Past rides
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2000 K1200LT
1992 K1100LT
2000 V Star 650/Velorex sidecar
1985 K100RT
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post #14 of 27 Old May 26th, 2015, 8:58 pm
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Re: Broken rear luggage handle.

Linton is referring to the two pins on the top side of the case. there is one pin for each latch lever on the lower half of the case. You only need to remove one C-clip to remove the upper half of the top case pin.
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post #15 of 27 Old May 27th, 2015, 1:51 am
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Re: Broken rear luggage handle.

Quote:
Originally Posted by saddleman View Post
Linton is referring to the two pins on the top side of the case. there is one pin for each latch lever on the lower half of the case. You only need to remove one C-clip to remove the upper half of the top case pin.
exactly

Regards Linton
From the land of Kangaroo's and Koalas
and no koalas are not Bears



2002 K1200LT
2010 Suzuki GSX 1250FA (the Wifes)
2004 Cub Kamparoo Sprint
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post #16 of 27 Old May 27th, 2015, 9:52 am
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Re: Broken rear luggage handle.

The latch handle is poorly designed by BMW. Those corners carry too much stress. I installed the FIBIB kit - luckily I didn't procrastinate. Both kits are very well engineered and precision machined. It is a lot of money but BMW would want to sell you a complete top case for 3x more.

Jim
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post #17 of 27 Old May 28th, 2015, 1:45 pm
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Re: Broken rear luggage handle.

Quote:
Originally Posted by Jim_McG View Post
It is a lot of money but BMW would want to sell you a complete top case for 3x more.
exactly

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post #18 of 27 Old May 28th, 2015, 1:48 pm
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Re: Broken rear luggage handle.

Quote:
Originally Posted by Foiler View Post
exactly
And even then you would have the same poor design destined to break again.

Jim
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post #19 of 27 Old May 29th, 2015, 1:42 pm
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Re: Broken rear luggage handle.

Quote:
Originally Posted by Jim_McG View Post
The latch handle is poorly designed by BMW. Those corners carry too much stress. I installed the FIBIB kit - luckily I didn't procrastinate. Both kits are very well engineered and precision machined. It is a lot of money but BMW would want to sell you a complete top case for 3x more.
I have had the FIBIB kit on mine for 6 years and it works great. My wife even though told many times to push down and shut it slowly forgets and wrenches it shut and if the FIBIB kit made it by her test (Consumer reports has nothing on her) they are tough.

Scott
2007 LT
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post #20 of 27 Old May 30th, 2015, 11:07 am
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Re: Broken rear luggage handle.

Is just one side broken? If so. Just remove the latch pin from the trunk lid on the broken side and get the fix it b4 it breaks kit.

2004 K1200LT. Big Mama
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post #21 of 27 Old May 31st, 2015, 2:27 pm
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Re: Broken rear luggage handle.

i found a lower half of the case on ebay cheep removed the non broken handel then used the fix before it breaks kit. it is a very high quality kit. it seems expencive but there is a lot machined parts to the kit
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post #22 of 27 Old May 31st, 2015, 4:11 pm
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Re: Broken rear luggage handle.

This is one of those, pay now, or pay later threads. I bought the "fix before kit" and I'm glad I did. When I installed the kit I noticed that one side had already started to deform/bend. It was not noticeable until I had a closer look when installing the kit.

Also remember that when you are doing this, you can also do the "Canisterectomy"

https://www.youtube.com/watch?v=GM81f5Y97ck

and the top box relocation, as its way easier to install the "fix it before" with the top box off.

https://www.youtube.com/watch?v=FYt_FmmqIWU

I ended up doing each one separate.


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Tross

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post #23 of 27 Old Jun 1st, 2015, 9:46 pm
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Re: Broken rear luggage handle.

I did a cheap repair on mine about 6 yrs ago & it still works fine. My wife & I are careful to push down on the lid & operate the latch paddle slowly & gently though. Here is an old post that shows a couple cheap fixes.

http://www.bmwlt.com/forums/other-st...ch-repair.html
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post #24 of 27 Old Jun 13th, 2015, 8:51 am
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Re: Broken rear luggage handle.

i have a fix before it breaks kit for 100 plus shiping. miine broke before i got the kit.
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post #25 of 27 Old Jun 13th, 2015, 7:49 pm
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Re: Broken rear luggage handle.

Quote:
Originally Posted by martin18152 View Post
i have a fix before it breaks kit for 100 plus shiping. miine broke before i got the kit.
PM sent

Steve
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post #26 of 27 Old Mar 4th, 2017, 6:45 am Thread Starter
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Re: Broken rear luggage handle.

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Originally Posted by james216 View Post
Is just one side broken? If so. Just remove the latch pin from the trunk lid on the broken side and get the fix it b4 it breaks kit.

Hi,

What is this "fix it before it breaks" kit that you guys are talking about ?

Mine is broken in the left hand upper corner, a small triangle broke off.

What does this kit looks like and do ?

Thanks.
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post #27 of 27 Old Mar 4th, 2017, 4:55 pm
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Re: Broken rear luggage handle.

An old post but still seems to be on going problem for new owners

its a kit you put on the handle before it breaks, someone on the site sells them not much good to you though,, you will need the whole kit. Once fitted it will never break again , did mine years ago.my mate broke his and removed the pin that was also years ago, he just repaired the broken corner and removed the pin. here is the link

If you dont want to fix it straight away remove the Pin on the left side of lock in the lid.
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Regards Linton
From the land of Kangaroo's and Koalas
and no koalas are not Bears



2002 K1200LT
2010 Suzuki GSX 1250FA (the Wifes)
2004 Cub Kamparoo Sprint
My Toys
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