Givi PL532 Side Rack - Stripped Bolts - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 14 Old 01-20-2010, 10:19 PM Thread Starter
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Givi PL532 Side Rack - Stripped Bolts

I finally received my Givi Side Rack (back ordered for 7 weeks) and followed the instructions...looked pretty simple. I aligned the left and right side of the rack, and loosely hand tightened the 4 M8x45mm bolts Givi provided and TWO of the bolts would not fully seat after several turns. When I had resistence, I backed them out and tried again...to no avail. I tried turning with more force, and likely made it worse. So...I've reseached this a bit and I saw a few threads about "chasing the threads" and/or "Heli-coil".

Can someone please provide me some insight as to which is the better method to follow? Can both be done by a non-mechanic type e.g. "me"?

Is this a "dealer" task? Any idea what they would charge to fix?

Can I purchase the kit at an auto parts store e.g. Advanced Auto Parts?

Is there a certain sized kit I need to use if the bolts that won't seat were m8x45mm that Givi provided?

If I "chase the threads" using the tool you suggest, do I use the same m8x45mm bolts Givi supplied or do I need a wider bolt if re-threaded?

Thanks much for your help! Totally frustrated I had to wait this long and botched the install on something that looked so simple :-(

***FIXED PROBLEM THANKS TO THE TERRIFIC HELP I RECEIVED IN THIS FORUM!!...SEE LESSONS LEARNED AT BOTTOM OF THREAD IF YOU ARE PLANNING TO INSTALL THE SIDE RACKS**

** 2006 Silver DL 650, Shad SH45 topcase, Givi PL532 Side Rack, Givi E360N side cases, Stebel Air Horn, Givi Engine Guards, Heated Grips, Madstad adjustable windshield brackets, California Scientific Windshield, Corbin seat, Highway Pegs, Yann designed Skidplate, Aprilia side mirrors, Powerlet Adapter, Metzeler Tourance tires, handbar extenders - North Atlanta / Alpharetta, Georgia **

Last edited by ckellyne; 01-21-2010 at 11:25 PM. Reason: SEE Reference to Lessons Learned I posted at bottom of the tread
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post #2 of 14 Old 01-20-2010, 10:46 PM
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Quote:
Originally Posted by ckellyne View Post
I finally received my Givi Side Rack (back ordered for 7 weeks) and followed the instructions...looked pretty simple. I aligned the left and right side of the rack, and loosely hand tightened the 4 M8x45mm bolts Givi provided and TWO of the bolts would not fully seat after several turns. When I had resistence, I backed them out and tried again...to no avail. I tried turning with more force, and likely made it worse. So...I've reseached this a bit and I saw a few threads about "chasing the threads" and/or "Heli-coil".

Can someone please provide me some insight as to which is the better method to follow? Can both be done by a non-mechanic type e.g. "me"?

Is this a "dealer" task? Any idea what they would charge to fix?

Can I purchase the kit at an auto parts store e.g. Advanced Auto Parts?

Is there a certain sized kit I need to use if the bolts that won't seat were m8x45mm that Givi provided?

If I "chase the threads" using the tool you suggest, do I use the same m8x45mm bolts Givi supplied or do I need a wider bolt if re-threaded?

Thanks much for your help! Totally frustrated I had to wait this long and botched the install on something that looked so simple :-(
You want to chase the threads with an M8 tap. I don't know if an automotive store would carry a metric tap and die kit, but I know some stores like Lowe's / Home Depot may. I got mine through a local store...Tacoma Screw.

You're effectively cleaning out the thread...sometimes dirt, debris or thread locker (Loctite, etc) can get in there and cause the bolt to seize when you are tightening it.

Are the bolts supplied by Givi in that kit coated in the same black material everything else comes in?

In that case, you may need a thread kit to clean the bolt itself, so it can fit.

Some people prefer to ditch the Givi bolts and purchase stainless steel hardware elsewhere...so it's not coated in that stuff.

I am sure there are much more informed members on this board that can answer your question better. They should be along shortly.

Also...you DO NOT need a heli-coil. That'll only be needed if you stripped the threads that the bolts go into.

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post #3 of 14 Old 01-20-2010, 10:53 PM
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Also, here a thread where a fellow Stromtrooper explains how to chase threads using an M8 tap (for Givi engine guards).

Givi engine guards thread chasing tip

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post #4 of 14 Old 01-20-2010, 10:57 PM Thread Starter
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Thank you for the feedback. Yes, the bolts Givi provided are coated in black but I think the problem is actually the two nuts in the frame of the bike the two bolts are trying to attach to. The other two bolts are fine. I've removed the bolts and used a nut I had and it fits the bolts fine and they both screw on and off with no problem. Thus, I believe I screwed up the threads in the nuts that hold the two bolts.....(excuse the pun) ;-) Does that make sense? Thanks again

** 2006 Silver DL 650, Shad SH45 topcase, Givi PL532 Side Rack, Givi E360N side cases, Stebel Air Horn, Givi Engine Guards, Heated Grips, Madstad adjustable windshield brackets, California Scientific Windshield, Corbin seat, Highway Pegs, Yann designed Skidplate, Aprilia side mirrors, Powerlet Adapter, Metzeler Tourance tires, handbar extenders - North Atlanta / Alpharetta, Georgia **
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post #5 of 14 Old 01-20-2010, 11:03 PM
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It helps to start each bolt using only a few threads at first. Only when all the bolts have been started should each one be turned in a few more turns each until all are tight. An M8x1.25 tap will clean up the holes and a die will clean up the bolts.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
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post #6 of 14 Old 01-20-2010, 11:13 PM Thread Starter
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Quote:
Originally Posted by LowAndSilent View Post
Also, here a thread where a fellow Stromtrooper explains how to chase threads using an M8 tap (for Givi engine guards).

Givi engine guards thread chasing tip
Thanks, I checked out that thread and I wonder if his post is telling the person he is trying to help to get new bolts because he will need wider diameter bolts after the tapping is completed since the hole of the nut the bolt will be seated in is now larger as a result of the tapping.

The bolt I was using was an m8x45mm...so the tap I need would be an 8x8mm tap? Is that right? Talk about a fish out of water here.

** 2006 Silver DL 650, Shad SH45 topcase, Givi PL532 Side Rack, Givi E360N side cases, Stebel Air Horn, Givi Engine Guards, Heated Grips, Madstad adjustable windshield brackets, California Scientific Windshield, Corbin seat, Highway Pegs, Yann designed Skidplate, Aprilia side mirrors, Powerlet Adapter, Metzeler Tourance tires, handbar extenders - North Atlanta / Alpharetta, Georgia **
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post #7 of 14 Old 01-20-2010, 11:17 PM Thread Starter
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Quote:
Originally Posted by greywolf View Post
It helps to start each bolt using only a few threads at first. Only when all the bolts have been started should each one be turned in a few more turns each until all are tight. An M8x1.25 tap will clean up the holes and a die will clean up the bolts.
Great, that is the clarification I was seeking. I need an m8x1.25 tap and I am assuming that I'll be able to reuse the M8x45mm bolts after the hole is tapped. Is that right...I won't need wider diameter bolts after the hole is tapped? Thanks much for the help.

** 2006 Silver DL 650, Shad SH45 topcase, Givi PL532 Side Rack, Givi E360N side cases, Stebel Air Horn, Givi Engine Guards, Heated Grips, Madstad adjustable windshield brackets, California Scientific Windshield, Corbin seat, Highway Pegs, Yann designed Skidplate, Aprilia side mirrors, Powerlet Adapter, Metzeler Tourance tires, handbar extenders - North Atlanta / Alpharetta, Georgia **
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post #8 of 14 Old 01-20-2010, 11:52 PM
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As long as you didn't strip the threads out of the holes, all sizes will remain the same.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general...nicknames.html

Please vote in the poll on what Strom(s) you have at https://www.stromtrooper.com/informa...-you-have.html
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post #9 of 14 Old 01-21-2010, 08:21 AM Thread Starter
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Quote:
Originally Posted by greywolf View Post
As long as you didn't strip the threads out of the holes, all sizes will remain the same.
I'll keep my fingers crossed. Thanks again!

** 2006 Silver DL 650, Shad SH45 topcase, Givi PL532 Side Rack, Givi E360N side cases, Stebel Air Horn, Givi Engine Guards, Heated Grips, Madstad adjustable windshield brackets, California Scientific Windshield, Corbin seat, Highway Pegs, Yann designed Skidplate, Aprilia side mirrors, Powerlet Adapter, Metzeler Tourance tires, handbar extenders - North Atlanta / Alpharetta, Georgia **
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post #10 of 14 Old 01-21-2010, 09:23 AM
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Originally Posted by LowAndSilent View Post
You're effectively cleaning out the thread...sometimes dirt, debris or thread locker (Loctite, etc) can get in there and cause the bolt to seize when you are tightening it.
I came across the same problem when installing crash bars. I found after removing the OEM bolts and before replacing with the ones provided with the accessory to ream out the hole with a pipe cleaner that has plastic bristles. I could not believe how much thread locker combined with grime came out of there. After I finished you could visibly see how clean the threads were, and the bolts went in without a problem. I've owned a couple of Kawasaki's and a Yamaha and none of them seem to have as much thread lock as the Suzuki. Not necessarily a bad thing, but just have to remember to clean the surface before slapping on the new farkle.

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