I wonder sometimes about the myth of BMW engineering excellence when I meet something like the fixing arrangements for the earlier KRS signal indicator pods.
Anybody whose had their plastics off a few times knows that the 'basket fixings' are awful. They are difficult to align, the fingers break off, the pods vibrate, the repair cost involves a new oem back plate and rivets need drilling to repair the corner basket.
Well at last I've found a fix. It's untried at triple digits, but I have every confidence the pods will stay on the bike.
Each pod is fixed to the front frame with 3 spring baskets rivetted to the ABS pod backplate which align with 3 steel tapered and grooved pegs screwed into the front frame plate (M5). These pegs, although a bit stiff, can be easily removed with a hex driver from the key hole in the center. The spacing distance between the ABS backplate and steel frame surface is 14-15mm.
I bought 6 rare earth Neodymium magnets for around $40. They each have a spec. pull of 7.5 Kg (16.5lb) so that makes 22.5 Kg (49.6lb) per pod. The part number is F431N 20mm dia x 10mm thick with 5.2 c/sink. I checked one magnet pull with a spring balance and it was 8Kg. The pods are not directly in the frontal airstream, being partly protected by the front tupperware. If you try this and are apprehensive, fit a safety tiewrap behind the pod to the frame.
Magnets are strong in pull but weak in friction so you must prevent the mated magnet moving against the steel frame. I did this by shaping a 5mm long centralizing spigot on the magnet holding screw. If you have a lathe you could do a really pro job.
The only real work is with a bench or angle grinder (caution watch pinkeys!). The parts are A2 stainless steel. I took a couple of M5 nuts (one is a backnut for holding), threaded them on a 50mm long bolt then ground a 45 degree chamfer on the nut. When finished the nuts must rest in the magnet countersink hole flat or just below the surface. The 5mm end of the magnet fixing screw was reduced and rounded so it would pass through the 5mm tapped holes in the frame. During assembly the taper nut and backnuts were Loctited. The 4mm thick rubber backing washer provides the correct overall spacing and some vibration damping.
I shall be doing some 'testing' over the next few days, but I'm optimistic that at last of got rid of those awful BMW baskets.
CAUTION: I kid you not these magnets are VERY strong. 2 magnets will attract and jump together when 7" apart! In this event, the shock or dropping on to a hard surface can chip or crack them. keep them away from metal or filings, they will find anything and stick hard.
You can find Neodymium magnets on Ebay or your local supplier. I've used these 2 sources:
In case anybody is thinking about 3M dual locks, they have a good friction pull strength but only a pound or so to separate them.
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