2012 EC200 Aluminum subframe conversion issues

[gascadia]

Long story short my gasgas got on the pipe too quick and I had to bail and throw it into a tree (better the bike than me!) It did some serious damage to the tree and the bike was mostly OK, but of course it snapped the plastic subframe, seat, and everything else back there. It also busted off a footpeg and bent the mount (why don't they have replaceable footpeg mounts like some other bikes?)

Anyway, I ordered an aluminum replacement subframe (part # BE12000CT-CAB-1 / BE12000CT-EKF-1) in hopes it would be more durable. For the most part it fits, but there are no threaded inserts in the top of the frame, as shown in the parts diagram. Only holes that are too big. Has anyone run into this before? I wonder if the inserts might be separate parts (not listed in parts diagrams), or if I have to do some fabrication (tap or otherwise install generic threaded inserts) to mount the plastics? Part of me wishes I had ordered identical replacement plastic subframe parts, but I know many conversions have been done and I don't want to do this again!

Here are some pictures of the aluminum subframe with (currently useless) holes, the original plastic subframe for comparison, and the clip that goes on the plastic subframe to allow the button head allen screws to thread in and hold on the plastic.

Subframe with unthreaded holes on the top:


Subframe Comparison:


Clip:

[SS109]

I think you might need to install nutserts.

[Anders]

in my '15 EC200 subframe there are popnuts / thread inserts. They may have forgotten to insert them

As I am going to do some wrenching tonight, I might post a photo later today, it you want me to.

[Anders]

Like these... They are M5


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[gascadia]

Anders,

Tusen takk for hjelpen og bilder! Jeg bodde i Surnadal et ar pa folkehogskole, ogsa i Lierbien naer Drammen flere maneder. Jeg likte norge veldig godt. Beklager, norsken min er lit darlig, men skal!!

na til engelsk...

I ordered the subframe from CPD here in the US, so I'll call them up and see if they have the inserts or know what might have happened. Worst case scenario I'll have to order the correct inserts from a fastener supplier.

Thanks again!

[gascadia]

Also thanks SS109, that is exactly what I need to do!

[Anders]

Originally Posted by gascadia

Anders,

Tusen takk for hjelpen og bilder! Jeg bodde i Surnadal et ar pa folkehogskole, ogsa i Lierbien naer Drammen flere maneder. Jeg likte norge veldig godt. Beklager, norsken min er lit darlig, men skal!!

na til engelsk...

I ordered the subframe from CPD here in the US, so I'll call them up and see if they have the inserts or know what might have happened. Worst case scenario I'll have to order the correct inserts from a fastener supplier.

Thanks again!

Nice one! Your Norwegian is actually surprisingly good, regarding you spent only a year here.
Lierbyen is quite close, only perhaps 45-50km from where I live, south of Kongsberg.
Tomorrow I am going to Rudskogen Motorsenter to do my first enduro race in a year, after a knee injury last May.

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