By October 4, 2006

How to Install a GIVI Side Case Bracket on a 2005 Yamaha FZ6

Introduction

This tutorial deals with installing the PL351 GIVI side case rack onto a 2005 Yamaha FZ6. These instructions should also suffice for 2004 and 2006 models, as they seem to be identical except for color variations. These instructions are not a substitute for the official GIVI instructions. They should be used as a supplement.

You must have the FZ351 top case rack installed before continuing. See How to Install a GIVI Top Case Bracket on a 2005 Yamaha FZ6 for more directions.

Tools Needed

  • 4mm Allen wrench
  • 5mm Allen wrench
  • 6mm Allen wrench
  • 13mm box wrench
  • wire cutters/stripper
  • pliers
  • flat head screwdriver
  • something with which to extend the turn signal lamp wires. I used crimpable, waterproof butt connectors, but you may want to consider something like Posi-Lock
  • 18 gauge wire
  • lighter/heat gun
  • A helper is strongly recommended. You may want to make sure they don’t have an aversion to foul language.

Instructions

  1. Remove the plastic clip on the opposide side of the right rear turn signal. You will have to pry it out from underneath the rear fender, I used a flat head screwdriver.
  2. Remove the turn signal. It will pull away from the fender when you have detached the clip. Be gentle, but firm.

    http://gallery.drfaulken.com/main.php?g2_view=core.DownloadItem&g2_itemId=4517

  3. One wire will be black, the other green (in the case of the right turn signal) or brown (in the case of the left turn signal). Mark the black wire with electrical tape so you remember which one is which later. Trust me.

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  4. Attach the top of the side rack with the 40mm bolt and a 6mm Allen wrench. You will remove the top bolt used for the top case rack.
  5. Remove the cotter pin and bolt for the passenger foot pegs. I used a pair of pliers to bend the pin enough to remove it. The bolt can be removed easily after that.
  6. Use a 55mm bolt, a flat washer, a nut, and a lock nut to attach the bottom of the rack to the passenger foot peg. Tighten with a 13mm wrench and a 5mm Allen wrench.
  7. Attach the U-frame with a 40mm bolt to the right side case frame by using the cone-shaped spacer and a 4mm Allen wrench.

    http://gallery.drfaulken.com/main.php?g2_view=core.DownloadItem&g2_itemId=4522s

  8. Place the turn signal in the signal extension mounting bracket. Make sure you attach it firmly with the plastic backing removed earlier.
  9. Extend the black wire from the bike’s original wiring to your new wire.
  10. Extend the green/brown wire from the bike’s original wiring to your new wire.
  11. Connect the black wire from the turn signal to your new wire.
  12. Connect the green/brown wire from the bike’s original wiring to your new wire.
  13. Seal the shrink-wrap sections of your butt connectors with fire/heat (if applicable).
  14. Repeat for the other side.

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