givi side case how to '07 zzr600

[tripntx]

Items to purchase:
L-Brackets ’00 – ’02 ZX6R
http://ventura-bike.com/english/prod...tem/index.html . Ventura bike is the manufacture in New Zealand, I can not remember who I purchased the brackets from stateside. Brackets were cut, hammered flat, bent, drilled, and touched up with black spray paint. They mount to the passenger foot rest bracket at bike frame to Givi side case holder. Our ZZR’s doesn’t have a bar underneath the frame that the ’99-’03 ZR7 has. These L-brackets solved the problem. Cut off piece is laying on the ground next to them.

Tubular side-case holder Givi PLB436, ’99 – ’03 ZR7 / ZR7S.
Left side attachment at passenger foot peg was easy, flatten bar some, and drill another hole in it.
Right side attachment at passenger foot peg required me to use a piece of scrape sheet metal between bar and foot peg.
Only other modification was bending my spare key, the tubular side case holder blocked access to open the rear seat, bent key solved that problem.
E21 side cases fit good, although the right one is barely touching the stock muffler. Maybe aftermarket cans are smaller diameter?

Top case holder Givi PB02 mounts without modification.

Here’s some pics of my bike with V46 topcase and Silver E21 Side Cases installed.

Enjoy,
Tripntx

[johnnyb]

You put many miles on that setup?  Might want to keep an eye on the case above the exhaust.  I know of a gentleman who managed to melt a hole in the bottom of his Givi side case....Not enough clearance between pipe and case bottom.
Cheers.

[tripntx]

Just mounted all of it yesterday, only 100 miles so far. I'm also concerned about melting a hole in the right case. Plan on two courses of action: 1) after market can, if smaller diameter, 2) thin sheetmetal heat barrier.

[tripntx]

more pics

[tripntx]

Just ordered a IXIL shorty slip-on exhaust can from indysuperbikes.com to solve the clearance issue on the right side. It's 5" shorter than stock.

[MK96xj]

Another nice job on your setup. Good room for the passenger too. Have you had you lady on the back yet with it and how does she like it? fit, comfort.

[tripntx]

My wife likes it, back rest is a bonus, and she would not have agreed to my buying a FJR or new Concours due to cost. Size of the E21 cases provides plenty of leg room for her and they don't stick out near as far as others I have seen. Plan on leaving them all the time. Installed the IXIL shorty exhaust, lots of distance between it and side case. Will add another pic soon.

[tripntx]

Just painted them to match my bike.

[JamesG]

Nice job!  

Did you just use rattle-can paint for that?

[tripntx]

Tape off area. Wet sand plastic with 320 grit or 260 grit wet n dry 3M paper (I used 400 grit and it took to long). Remove tape once plastic is sanded smooth, apply new tape.
Spray sanded area with Plastic adhesion promoter, use two light coats, 10 minutes between them. Let dry 20 minutes.
Spray three coats of Flexible primer, 10 minutes between coats. I allowed the primer to dry overnight before sanding it.
Wet sand primer & factory painted top surface of side cases with 600 grit 3M paper.
Remove tape and then apply fresh tape. Clean all surfaces with Wax & Grease remover.

Kawasaki Candy Fire Red requires a silver base coat with a translucent red top coat. Took 3 coats of silver to cover, then took 7 coats of red, followed by 2 coats of clear. It appears 5 coats of red would have been better because mine turned out a little darker than factory red. Used a Nesco HVLP gravity feed spray gun with air pressure set at 35 lbs. Fluid needle 1.5 turns out for color, 2 turns out for clear, is 1.6 mil size. I do have previous training from my earlier years with painting autos.

Modified my storage shed into a spray booth using plastic sheeting from Wal Mart.

Silver & Red where purchased from www.colorrite.com at $110 per pint of color. Purchased all other items from local automotive paint store for $350:
NESCO HVLP gravity feed spray gun
Spray gun stand
One quart clear with catalyst
One quart reducer for the color
Tack rags
Adhesion promoter
Flexible primer surfacer
Sandpaper
Etc

This is an expensive project which I wouldn’t have undertaken without spray painting experience. I spent a total of 20 hours last weekend sanding, prepping, priming, sanding, prepping, painting.

[JamesG]

A simple "no" would have sufficed.  

[MK96xj]

Nice job. Here is to keeping the shiny side up after doing what sounds to be alot of work.

[tripntx]

A simple "no" would have sufficed.  

Didn't mean to offend, had just posted directions on another forum for I copied and pasted them here.

[MK96xj]

Didn't mean to offend, had just posted directions on another forum for I copied and pasted them here.

I'm sure JG was joking due to the length of detail

[JamesG]

Yeah just kidding man.  I toyed with the idea of painting my E-21 Yamaha "blurple" to match my YZF, but decided it was more work than it was worth for me.  But it does look really good on yours.

[tripntx]

I guess that post was just a little bit long winded.

[Joey Stalin]

Finished my install this weekend. First, the top crossmember went on lickety split, no problem.




Now the left side - several interesting things to point out. My hole was drilled in a different location than yours. I also used the supplied M6 x 60 socket head bolt for the left side, to get through the extra material. It really needs to be 65 or 70mm long, but I couldn't find any. Also you could substitute a #12 bolt x 2.25" long, but that's also difficult to find.




And the key for the seat isn't blocked at all. Did we get the same kit?....



The right side is also different than yours. First thing I did was drop the exhaust down with a simple piece of 1/8" steel, and drilled two holes in it about an inch apart.



This gave me the room I needed to clear the side case.



And this is where the right side bracket is located. Also different than yours:



Now comes the ugly part. I took a 1" strip of 1/8th inch steel from the shop at work, and hammered, pounded, and smashed until I got it into a shape that connected the end of the Givi rack to the bottom of the passenger footpeg.




1/8" mild steel is plenty strong enough and easy to work with a heavy iron mallet. I didn't even have a vice handy, just used a wooden table edge and a C clamp. It's not pretty, but it works and it wasn't too hard.

The finished product:




Now I don't know why ours are so different. I bought the kit for the ZR7, same part number PLB436, but mine lined up different than yours. Who knows. So far I've put about 300 miles on everything and it is steady. I've watched the bags while going down the road (do not try this at home, kids) and they vibrate up and down just a little bit. If I remove the side reflectors, it will be very easy to tie the left and right side together for added rigidity. I plan on using, again, a simple strip of 1/8" steel to do this.
Won't even need to hammer it.



I haven't moved the turn signals yet, either. They don't interfere with the bags but you can't see them from the side.

[tripntx]

Yep, yours lined up different. Givi apparently placed a different product in our box's. Oh well, they still worked. Really like the way your E21's slant down at the front.

[Joey Stalin]

So who's is the right kit?

[ZZRrocket]

Finished my install this weekend. First, the top crossmember went on lickety split, no problem.




Now the left side - several interesting things to point out. My hole was drilled in a different location than yours. I also used the supplied M6 x 60 socket head bolt for the left side, to get through the extra material. It really needs to be 65 or 70mm long, but I couldn't find any. Also you could substitute a #12 bolt x 2.25" long, but that's also difficult to find.




And the key for the seat isn't blocked at all. Did we get the same kit?....



The right side is also different than yours. First thing I did was drop the exhaust down with a simple piece of 1/8" steel, and drilled two holes in it about an inch apart.



This gave me the room I needed to clear the side case.



And this is where the right side bracket is located. Also different than yours:



Now comes the ugly part. I took a 1" strip of 1/8th inch steel from the shop at work, and hammered, pounded, and smashed until I got it into a shape that connected the end of the Givi rack to the bottom of the passenger footpeg.




1/8" mild steel is plenty strong enough and easy to work with a heavy iron mallet. I didn't even have a vice handy, just used a wooden table edge and a C clamp. It's not pretty, but it works and it wasn't too hard.

The finished product:




Now I don't know why ours are so different. I bought the kit for the ZR7, same part number PLB436, but mine lined up different than yours. Who knows. So far I've put about 300 miles on everything and it is steady. I've watched the bags while going down the road (do not try this at home, kids) and they vibrate up and down just a little bit. If I remove the side reflectors, it will be very easy to tie the left and right side together for added rigidity. I plan on using, again, a simple strip of 1/8" steel to do this.
Won't even need to hammer it.



I haven't moved the turn signals yet, either. They don't interfere with the bags but you can't see them from the side.

What kits did you purchase and where?  

[Joey Stalin]

This is exactly what I ordered:
http://www.twistedthrottle.com/trade/productview/123/96/

Seems to be some discrepancy between what I bought and what Trip bought, but they both worked.

[tripntx]

After looking at yours and then walking out to mine, figured out we used different mounting tabs to attach the tubular rack to the cross bar. I attached to the tab on top, which allowed my V46 mount to be mounted futher back and level. Your's is attached to the tab futher back, which moved yours forward and tilted the rack to a pleasing angle.

Either way will work, both kits are the same.