Nothing ever fits the way you're told it will.

Just in case there is anyone else out there wanting to fit a Givi top-box to the rack on their Suzuki DL650, here is the way I did it.

You will need the following:
1 x 6mm twist drill
1 x drill
1 x set of allen keys
1 x 10mm spanner (slim with long handle is best)
2 x 30mm diameter washers (outside diameter)
1 x rule
1 x metal scribe
1 x small socket set.
1 x DL650 (mine is an 06 model)
1 x Givi Top-box with supplied mounting plate and fastenings (Mine is a E370N)

Step1.
You will need to remove the rack from the back of the bike. In case you didn't notice, there are 4 bolts holding this on. Two at the top of the rack itself and two under the seat.

Step 2.
Remove the rubber mat from the top of the rack. A small amount of spray-grease will help pull the rubber plugs through the holes. Store flat, in case you want to put this back on at some point. (I guess you could drill through the rubber but that would look rather tatty if you ever took off the top-box permanently.)

Step 3.
Finding the best position for the Givi mounting plate is tricky. The rack plate has reinforcing ridges underneath and these frustratingly line up with just about all the bolt option in the Givi plate. I found just two that would line up without the need to remove some of the strengthening ridges underneath. You'll know what I mean when you turn the rack over and look at the under side.

I was able to use an existing hole in the rack, but had to drill a second. The following image shows where I put the extra hole. I'm hoping two will be sufficient and it feels very solid.

Step 4.
Test fit the Givi mounting plate to the rack to check for fit and alignment. You will need to remove the mounting plate again as you won't be able to put in the two rack bolts that hold the rack on the bike.

Step 5.
Re-attach the rack to the bike, replacing the 4 bolts and do try not to strip the thread.

Step 6.
Attach the Givi mounting plate to the rack.

This is rather tricky. You will notice the recess that the rubber mat came out of (not shown). If you don't place one of the 30mm washers between the rack and the mounting plate, as you tighten up the bolts you will distort the plate which will make attaching the top box almost impossible. Do yourself a favour and remember the washers. I used two bolts, so needed two washers to act as spacers. The following image shows the back most spacer.

Only attach the back bolt to finger tightness at this stage. You can use one of the supplied W brackets for this bolt. I found there wasn't enough room to use one on the second bolt.

Position the mounting plate and push through the second bolt (remembering the washer between the rack and the mounting plate)

Attaching the second nut will be a challenge, but if you have a long handled 10mm spanner you'll be fine. Don't forget the small washer and remember you may not have space to use a W bracket.

Don't fully tighten bolts just yet.

Step 7.
Test fit the the top box. If you can attach and remove it easily you're done. If not, you may need thicker washers to act as spacers between the rack and the mounting plate.
Tighten the bolts, don't strip the thread.

Step 8.
Replace the cover to the mounting plate, and attach the top box.

You're done.

Tags: motorcycles