I love my new 2009 Yamaha FJR1300A. It is very nimble for its size, has lots of power, and is fun to ride. One of the things I don’t like about are the factory side cases. They are probably just a little bigger than my old Givi E21 panniers (21L capacity), but definitely smaller than the E360 cases (40L capacity) I have on Cylon. I am not sure what the displacement is on the factory side bags, but I would guess they are somewhere around 25L.

Anyway, Givi doesn’t make a Monokey side rack for the Generation 2 FJR1300A (that’s model year 2006 and newer), so using my E360s on Apollo is out of the question. Buying the latest and greatest Givi side rack and side cases would set me back almost $900 before shipping, and I am not ready to make that plunge.

So I bought the biggest fucking top case I could find — the Givi E55 Maxia hard plastic top case.
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I’ve grown accustomed to having a lot of storage on my motorcycle. I try to ride as much as I can, and that includes trips to Target or the grocery store. Before I signed the paperwork for my FJR1300A I put in an order for the Givi SR357 top rack from Twisted Throttle. As usual, Twisted Throttle’s customer service was top notch. I made the (somewhat silly) request to include more than their one traditional reflective logo sticker. They sent me three ;) Good on you, Twisted Throttle!

So, my previous Givi rack installation experience was with my 2005 Yamaha FZ6. In short, it was a total pain in the ass. You learned a few new words if you lived within two miles of me. I had to use a rubber mallet to make the rack fit correctly and I think I seriously damaged my relationship at the time due to my behavior. With that in the back of my head, I was prepared to spend hours putting the SR357 on my Yamaha FJR.

I was very surprised that the installation, from unpacking to clean-up, took less than thirty seven minutes.

Here’s how to do it.
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When I sold Raider, my BMW R1150R, I knew I would immediately miss the greater storage capacity. Sure, my Yamaha FZ6 Cylon has the Givi V46 top case and E21 side cases. Even though Raider had the ultra-wimpy E350 Flow case (35L instead of the V46’s 46L), I felt like I had more space on the BMW due to the massive side cases.

However, I didn’t want to spend $200 each on getting the 40L Givi E360 side cases. I started looking around for alternatives, and found a thread on ADVrider.com about JC Whitney’s hard cases. They are a knock-off of the E360, and by all accounts they were not as well made as their Italian inspirations. Yes, there were accounts of them flying off of the supplied mounting rack at highway speeds, or that the interior “stays” that held the clamshell design open snapping on first use. Yes, there was that stupid iron cross sticker on the top. However, they were cheap, at about $85 before shipping.

The more I read, the more intrigued I became. The rumor was that with some “fine tuning” they could be modified to fit the existing Givi rack on my bike. I was already ready to try them out, but when I found a way to get them for less than $65 shipped I was chomping at the bit.
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I have been unhappy with my 2002 BMW K 1200 LTE ever since my trip to Georgia in the spring. The bike is too big and top heavy for riding around town (or in a traffic jam), and has such a big aerodynamic profile that a side-wind makes the bike feel very unstable. I also think the bike was a little too advanced for me to ride in substandard conditions, and if there was any hint of poor weather I’d opt for my FZ6 instead.

So, I put Raptor up for sale on Craig’s List. I got a lowball offer and declined it. Then I heard from a fellow in North Carolina, offering to trade me his K 1200 RS, the sportier version of my bike. I replied, stating that I wanted something smaller and more street-friendly. I didn’t expect to hear back from him, but he replied a few hours later offering his 2004 R1150R plus some cash. I bit.
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After installing the GIVI FZ351 top rack I installed the side racks required to carry my saddlebags. The side rack was in some ways easier than the top rack (all of the pieces fit without the use of a mallet, for example), but in some ways more frustrating. The clips that hold the turn signals on are a MAJOR pain in the ass if you have even medium-sized hands, and the top rack installation didn’t require any rewiring. I finished this install in about two or three hours with the help of my friend Duke, who helped me reinstall the rear flashers. Trust me, you’ll want a compadre on this one.

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.

   

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.

   

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.

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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.

Introduction

This tutorial deals with installing the FZ351 GIVI toprack case rack onto a 2005 and 2006 Yamaha FZ6. These instructions should also suffice for 2004 model, as is seems 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.

Note: this is a reprint from my wiki article. Thanks to Sp8z and Kyle for edits and help. I have left their edits and tags intact.

Tools Needed

• #2 Phillips screwdriver
• 4mm Allen wrench
• 5mm Allen wrench
• 12mm socket
• 13mm box wrench
• flathead screwdriver
• rubber mallet
• scissors
• A helper is strongly recommended. You may want to make sure they don’t have an aversion to foul language.

Instructions

Removing the plasticy bits

1. Remove the seat.

2. Remove the bolts holding the plastic fenders of the FZ6 using a 4mm Allen wrench.

3. Remove the bolts holding the tail lamp/sissy bar plastic assembly with a 12mm socket.

4. Remove the fender by pressing against the retaining flange with a flathead screwdriver. Apply the flat of the blade (not the tip) of the screwdriver against the tip of the flange. The other flange will pull away easily after the first one is released.

5. Remove side bolts using a 12mm socket.

6. Detach the brake light plug from the wiring harness on the left side of the bike by pulling it apart with your hands.

7. Remove the two screws underneath the tail lamp/sissy bar plastic assembly with a #2 Phillips screwdriver.

8. Remove the tail lamp/sissy bar plastic assembly by pulling towards the end of the tailpipes. There is a flexible plastic tab you will have to manipulate free by pulling straight back.

Attaching the top of the tubular rack

1. You may have to remove the exhaust cover. One of the tubes on my frame was missing a cap and had room for the rack. The other cap was still on, and was obstructed by the exhaust cover. You may be able to remove the exhaust cover with a #2 Phillips. All I managed to do was strip the heads on the over-torqued screws. I improvised by bashing the exhaust cover down with a rubber mallet. God forgive me.
Edit by Sp8z: You may be able to remove the screws by using vice-grips on the edge of the screw head to get it started. I replaced these screws with hex cap screws from a hardware store. Edit by Kyle (‘07 FZ6): I put a #2 Phillips bit into a socket wrench and used that to free it. Worked very well.

2. Build the cylinder assembly by putting the cone-shaped nut into the cylinder ”’narrow side first”’.

3. Use a rubber mallet to hammer in the cylinder assembly. Edit by Sp8z: The cone is used to flare the split cylinder and lock the cylinder in place. Install the 65mm screw to keep the cone from coming loose and rolling into the frame. Don’t tighten the screw super tight, just until the screw head is against the cylinder. If it doesn’t go easy, loosen the screw. Shouldn’t take more than 3-4 hits to seat the cylinder.

4. The GIVI instructions tell you to insert the 65mm bolt into each cylinder assembly, and to not tighten them all the way with a 5mm Allen wrench. In retrospect, I believe this step is unnecessary, as you wind up removing the 65mm bolt again in order to mount the frame onto the cylinder assembly. I am leaving this step in the process for completion’s sake. Edit by Sp8z: At this point the screws should already be installed. After the cylinder is installed, crank on the head to force the cone into the split cylinder to lock the cone and cylinder into place. Once the cone and cylinder are locked into place, remove the screw.

5. Apply the protective foam-backed tape to the C-shaped pieces. Cut the excess with scissors.

6. Re-attach the muffler cover if necessary. Edit by Sp8z: When I put the muffler cover on, the cylinder didn’t allow the muffler cover screws to line up. I used a dremel tool to remove a small portion of the muffler cover. I also replaced the aluminum philips head screws with steel hex cap screws.

7. Put the 20mm bolt and flat washer provided by GIVI into the bottom mounting hole. Use the “hat” piece from your FZ6 on the other side. Use a 5mm Allen wrench. I swore up a storm during this step: helping hands are definitely recommended.

8. Insert the 65mm bolt from step 4 through the top part of the C-shaped piece. Do not tighten all the way.

9. Attach the top rack arm by screwing a 25mm bolt to the C-shaped piece. Use a 6mm Allen wrench to tighten it most of the way.

10. Put a 20mm bolt and a split washer into the bottom mounting hole. Reuse the hat from step 7. Tighten completely with a 5mm Allen wrench.

11. Tighten the 25mm bolt from step 9 completely.

12. Tighten the 65mm bolt from step 4/8 completely.

13. Put the 25mm bolt through the smaller 6mm washer. Run these two through the top case mounting plate. Secure the bolt with a 6×18mm washer and nut. You will only use four 25mm bolts on the FZ6, even though there are six holes in the top case mounting plate. Tighten with a 5mm Allen wrench and a 13mm box wrench.

14. Place the black plastic caps over the holes in the top case mounting plate.

After burning several hours, my previously-assumed inexhaustible supply of swear words, and the patience of Lady Jaye, I managed to put the GIVI hard luggage top case rack on my 2005 Yamaha FZ6. The original instructions were in Italian, and the English translations weren’t very descriptive. I did my best to take notes and pictures in order to document this process to future sufferers. I mean, FZ6 owners.

I would summarize the install thusly: fucking heinous. If I had to do it all over again, I would have taken the top case and side case racks to someone to do the installation and wiring. With parts of my bike not aligning properly (and requiring the use of a rubber mallet for “fine tuning”), I thought the worst was over when I put the top case on. Little did I know that this would be one of the easiest parts of the whole affair. Holy shit.

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

I’ve got a long write-up forthcoming on installing these bad boys, but I received my GIVI V46 and E21 hard cases today.

The hard cases afford me a few minor luxuries my soft bags did not:

• they lock, to keep casual crimes of opportunity from happening. I was always nervous about someone unzipping my soft bags and rummaging through them.
• they hold more. The topcase alone has 46L of capacity and can eat two helmets side by side.
• they are waterproof. While my softcases had rain covers, it will be nice to not have to worry about rushing out in the middle of an event to put them on. I was nervous about the rain covers blowing off at speed anyway.