• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Te 630 Sub-frame Mod

Kenneth Webb said:
Wrryder, I never really thought about making plates. They are very simple to fab and can be done with a hack saw and a hand file in a few minutes, for pennies. The welding is the trick, and needs to be done properly. Of course you have to pull the bike apart too, then put it together again and not everyone is going to do that. If you have TIG welding equipment available, and good skills, go for it! Listen carefully to any stock sub-frame and you will hear it pleading for help....
Click to expand...

I know how good you are at making kick stands so if you sold plates I'd want mine autographed. :busted:
 
Ken is right, they are really easy to shape with simple hand tools. And can be bolted on by just removing both rear fenders and pulling up the battery box. It's cheap and it works really well.

I've always said doing a proper weld job is really the way to go, but it's a lot more complicated and requires a lot more disassembly. Plus the more you beef up the sub back there the more it puts strain elsewhere. I've heard of bent and broken lower mounting bolts, and cracks along welds. DO NOT PUT HARDER BOLTS IN THE LOWER MOUNT. Bend them, replace them, you don't want to break something else.

So beef it up one way or the other, then take it easy on this assembly. It's not made for carrying a lot of weight. This is a dualsport, not a round-the-world adventure bike.
 
Did mine over the weekend:

IMG_3154.JPG
 
Got 2 of these spare if anyone is interested. I also have a metre of aluminium flat bar. I got 2 extra u-bolts from Husqvarna but I don't need them now. £20 for bar and U-bolts.
IMG_3766.jpg
 
I was hoping my giant loop hooks would reach those brackets, since I removed the passenger grab handles. No go. The bag straps aren't long enough. I just put the hooks on the plastics; should be fine.
 
jtemple said:
I was hoping my giant loop hooks would reach those brackets, since I removed the passenger grab handles. No go. The bag straps aren't long enough. I just put the hooks on the plastics; should be fine.
Click to expand...

Make an extension loop with a bucklet to connect to. Straps are easy to customize and configure. I would not hook to plastic, the stuff barely holds onto the bike. lol.
 
hi, have now got 3000k on my 630 & thought the rear subframe would be fine{yes all these posts are here for a reason}ihave a tci rack & kolpin 5l fuel container, the rear frame broke the other day & had to limp the bike home & yes its a bit of a job to remove the sub frame,i had mine re welded & gusseted as seen on this site & refit & now its as strong as ever,fool me thinking she will be right mate!so any new 630 owners reading this take cj browns advise & make up the brackets shown here as its a lot easier than what ihad to do
 
Which TCI rack?

I just beat the hell out of mine for two weeks w/ a heavy load and guarantee it would have broke but for CJ's mod.


.
 
As much as I like TCI stuff, I think they should recommend frame mods w/ those racks (maybe he does?). He does with the Outback rack and IMO it's needed less w/ it than others because it carries a lot of weight/vibration down to the rear footpegs.

7-27-12031a.jpg




.
 
I emailed for a few month to couple of the luggage makers -- nobody is planning/making luggage rack that distributes weight out of the subframe.

I am playing with ALICE frame (LC-1) mil surplus frame to see if can mount on the sides with simple straps (attaching to passenger footpeg for good load bearing and passenger handle)
Notice also the bag when mounted would slightly go over to the left outside of the heat shied
so I plan to install giant loop heathsield that costs more than the alice frame and bag (http://www.giantloopmoto.com/products/hot-springs-heat-shield)

Do you guys think it is a horrible idea?

alice_frm_1157.JPG
 
Worker, it looks to me that the bags are way too far forward! Your legs will be right up against the bags, and you will be sitting partially on top of them. It is going to impair your ability to use your feet and legs, and make it almost impossible to move your weight back when needed. Do a full mock up with the bags loaded to make sure you are happy with the position, all other considerations aside for starters.
 
worker said:
I emailed for a few month to couple of the luggage makers -- nobody is planning/making luggage rack that distributes weight out of the subframe.

I am playing with ALICE frame (LC-1) mil surplus frame to see if can mount on the sides with simple straps (attaching to passenger footpeg for good load bearing and passenger handle)
Notice also the bag when mounted would slightly go over to the left outside of the heat shied
so I plan to install giant loop heathsield that costs more than the alice frame and bag (http://www.giantloopmoto.com/products/hot-springs-heat-shield)

Do you guys think it is a horrible idea?

View attachment 19863
Click to expand...

I think you would be better off with some Wolfman racks. Trail tested in my case and they are designed to transfer quite a bit of weight off of the rear of the subframe.

Husquvarna-te630-right.jpg


Husquvarna-te630-left.jpg


IMAG0548.jpg
 
+1 on the Wolfman setup. It's not cheap, but you get what you pay for. If they survive the hammering they take in Death Valley, especially down the Saline Valley Rd, they will survive about anything. I have them on two bikes, and never any issues. Of course, my 630 sub-frame is reinforced too, for insurance.
 
djc said:
hi, have now got 3000k on my 630 & thought the rear subframe would be fine{yes all these posts are here for a reason}ihave a tci rack & kolpin 5l fuel container, the rear frame broke the other day & had to limp the bike home & yes its a bit of a job to remove the sub frame,i had mine re welded & gusseted as seen on this site & refit & now its as strong as ever,fool me thinking she will be right mate!so any new 630 owners reading this take cj browns advise & make up the brackets shown here as its a lot easier than what ihad to do
Click to expand...

Like a goose I didn't listen... Went for a squirt through the Belanglo State Forest yesterday, too lazy to wash the bike afterwards as I'd been on it for 8 hours. So this is what greeted me this morning:

Break 1.JPGBreak 2.JPGBreak 6.JPGBreak 3.JPGBreak 4.JPGBreak 5.JPG

I was only carrying a Wolfman Peak Tailbag containing tools & a spare tube, on the standard Husky rack. Probably the 2nd & 3rd gear jumps on firetrails that did the damage. Am surprised, as the weight wasn't much. Husky shouldn't offer a rack if the bike can't carry anything on it without breaking.
 
Russ said:
Like a goose I didn't listen... Went for a squirt through the Belanglo State Forest yesterday, too lazy to wash the bike afterwards as I'd been on it for 8 hours. So this is what greeted me this morning:
Click to expand...

I too with red face must admit to the same mistake. After 13 months and 14,000 miles my subframe met the ghost last week also. Just returned from a week riding rocks in the desert. Halfway through the 6th day my rear end was flapping same as Russ's photos. I thought I was too old and smart for it to happen to me but instead I guess I was just too stubborn and stupid. I also limited weight on the rear and was somewhat reserved when jumping thinking that would save me. However a week of banging over big rocks and being forced to jump many wash outs, ruts and crevices or else turn around or go way off trail was too much I guess.

My subframe actually cracked in two places on each side. I'll post some photos after getting the bike washed and stripped down.

There is a little silver lining in this for me though I guess. Once subframe rewelded and reinforcement gussets added in I will no longer be reserved when hitting whoops and jumps off road now. My fun factor will go up significantly.

_
 
Has anyone who has done the bolt on reinforcing checked after a trip loaded to see if there's any stressing marks on the subframe ?
 
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