Givi Crash Bars install Problem

[noresttill]

Hello everyone,

I just got a set of Givi Crash Bars for my wee and having a problem with the bolts that go through that adapter plates. It seems that they are cross threading, or that there is junk in the threads. I was turning them down a little, then backing them out and cleaning the junk off, repeat... but im going to get my tap set from work tomorrow.

Anyone else have this problem?

Thanks

[blaster007]

Yes. I had the exact same problem. But the collar the bolt went in to broke loose. I couldn't get the bolt back out. I returned the set i had and now they are back ordered from my local dealer. I wish i would of chased the threads first,but why should you have to when buying something new... Mass produced junk:frown2:

[noresttill]

That is the same thing that happened to me! This is actually my second set, so im not making the same mistake twice.

Thanks for the resonse, at least i know its not just me.

[barry]

Same problem here. Called Givi and the recommended spraying WD-40 in the tube and let it dissolve/soften the loctite that was probably in there. Didn't seem to work. I just kept screwing it down with much force hoping that the heads wouldn't strip....they didn't. It helps to have a T-handled hex key or hex sockets that fit into a wrench. Not enough leverage on the little L-hex key.....it will make you cuss and yell and you'll scare your wife.....don't ask me how I know. No audible vibration on the crash bar that others have mentioned but I do wear a full face helmet. My biggest installation challenge was getting them to fit with SVRacing frame sliders. Had to file the right side down (left side fit without alteration......not sure I understand why). Of course I filed out too far on the slider and looks pretty ugly.

Hope this helps.

[barry]

What does "chased the threads" mean?

[weekend_warrior]

Chasing the threads means to take thread tap and follow the threads in the hole to get out the gunk (leftover anti-seize or loctite). If a bolt has been X-threaded in there it screw up the good threads and the tap will chase the good ones and help the bolt seat correctly.

[barry]

Thanks. Is that like a tap and die set?

[noresttill]

Yes, a tap and die set.

I just "chased" the threads and you wouldn't believe the shavings! Anyway, it takes a M8-1.25 tap and works fine now, problem solved.

If you dont already have a tap set and cant borrow one, add that price the the total when shopping for crash bars.

BTW, all the other bolts are the same size and pitch.

Good Luck!

[Rforce1]

There seems to be a lot of threads regarding this topic.
Here's my post about possible SS Bolt alternatives:
http://stromtrooper.com/showpost.php?p=321102&postcount=13

[ScottyUSN]

Just installed mine, same issue. Poor fabrication, and pathetic fasteners.

[noresttill]

my theory is their tap has been resharpened too many times

[Canvas6st]

I wish I had known about this before I installed my bars today. I do like the look and the higher protection of the Givi bars, but those bolts were garbage! Oh well, the bars are on, and hopefully won't have to come off any time soon.:weapons_6:

[iloco]

Can someone tell me what size tap a person needs to chase the threads. I am having same issue with the givi bolts. :(

[weekend_warrior]

I will look tonight. My bars should be coming today. The brown guy usually with the Ding-dong-ditch on my porch around 6:00 P.M. Once I have the bolts I an use the thread guage on them.

If you take the bolt to lowes and use there little sizer board (has a buch of different size threaded holes in it). It will tell you the thread pitch and size. I have a set of guages at home as well as a small meteric tap set. I use them enought that instead of buying just the one I need I bought a set of 5 or 6 of the most common sizes. Sure is nice to know what size bolt you are looking for before leaving the house. It's really great if you need to call head to make sure something is in stock.

http://www.boltdepot.com/Thread-Gauges.aspx

cool printable ones:

http://www.boltdepot.com/fastener-information/Printable-Tools/Default.aspx

[iloco]

Thnaks for reply. I will check Lowes when I am at their store. The nearest one to me is like 45 miles from where I live. :)

[weekend_warrior]

Hopefuly I will tackel this tonight. Didn't have have to open the box last night.

[iloco]

Thanks weekend_warrior.
I got my crashbars today but will wait until I see how yours go and what size tap you used on the threads. :)
I hope your install goes ok. :)

Let me know how the replacement bolts worked that go into the motor support where the originals were. :)

[weekend_warrior]

I didn't find the bolts all that bad. I tapped the powder coat out of the treads on the bars with a M8X1.25 tap. The bolts were just coated with what looks like an industrial paint similar to the bolts on my DR350. Not a proablem.

I used a breaker bar and socket hex to get the OEM bolts out. Worked great. They used green thread lock. I used a engine block brush and contact cleaner to remove the old loctite from the frame. I put the Givi bolts in with blue loctite and used anti-sieze on the bolt that holds the bar to the mount. I torqued the bolts to 16.5 ft.lbs on the frame.

I also left everthing loose on the left side and then put the right side on. I connected the bar under the engine and tightened it first. Then torqued the mounts on the sides.

Took my time and it was easy.

The torque setting came from this thread:

http://www.stromtrooper.com/showthread.php?t=35522

P.S. The instructions were crappy. Only pictures basicly, but nothing to hard about it.

[iloco]

Thanks for that very good install instructions.
I have to find me the tap and some anti-sieze before attempting my install. Looks like it may be a few days before I do the install because we suppose to get bad weather today and then get cold again. I don't have any heat in my barn where I store my bikes. :)

Anyone know where you can buy single taps. I need a M8 X 1.25 and a M6 X 1.00. I hate to buy a complete set to just get these two. :)

[weekend_warrior]

Most any auto parts store should have that. How about the local hardware store? We have specialty bolt shop in town that carries them. Sears will also have them in singles. You could also order them online, but have to pay shipping. Would save driving into town, but at 45 miles into town it would make a nice ride on the V-strom if the day is good.

[iloco]

My son said he had some anti-sieze at his work place and also has the taps I need. That will take care of the install problem once I get the threads chased. :)
I have read to many threads where people have trouble so I want to be sure and do it right as you have done. :)

[greywolf]

There is no need for anti-seize in crash bar installations. Cleaning up threads with taps and dies can help if there is paint or powder coat on any threads or if the bolt threads are not in excellent shape. It's been reported that Givi bolts are poor quality but I don't have personal experience there.

[iloco]

Installed my givi bars today and everything went great.
I used a tap to clean all the threads before putting the replacements ones in. :)
Now if spring will arrive maybe can take a couple trips and enjoy the setup I am now finished with. :)

[Crooz650]

Just finished an installation.... screws were tight, but no problems nor cross-threading here.
One needs to take their time and insure the bolts are aligned and going in straight... don't rush.

[McJamie]

Mine went in no problem. As a side note, a year ago I was hit broadside by an SUV with these exact guards on my 650. I got luanched into the air and landed on the other side of the road. The bike slid a good 70ft on it's side ( it was wet), went up over a curb, and stopped in a parking lot. I called my friend and he [B]RODE[B] the bike home. the signal was torn off and a couple of small scratches, but no major damage. I went to the hospital on a backboard. Best $150.00 I could have spent. McJamie.