Instructions for custom fitting Givi V35 PLX side cases to the BMW

Instructions for custom fitting Givi V35 PLX
side cases to the BMW K1300S and K1200S
by Harry Burney September 2013
Design criteria for custom fitting of Givi V35 PLX side cases to the K1300S and K1200S
As described in the companion article on this website, the author selected Givi V35 PLX
side luggage to install on his K1200S in 2008 and transferred the racks and cases to his K1300S
in 2011. This article describes in detail how Givi PLX687 side racks, designed for the BMW
F800S, were modified to fit his K1200S and then his K1300S.
To take the advantage of the curved shape of the Givi V35 side cases to better fit the rear
bodywork of the K1200S, I decided to lower the rear portion of the muffler. Because the
connection between the exhaust header and the muffler is a type of ball and socket joint, the
muffler is able to swivel down on both the K1300S and the K1200S. Thus, to lower the muffler,
all that is needed is a new mounting bracket. Even the heat shield below the right foot-peg can
be retained with the muffler lowered as shown in Photo 1. The criteria for locating the luggage
and the luggage racks were: 1. As close as possible to the motorcycle rear bodywork without
damaging, cutting, or modifying said bodywork, 2. As low as practical with respect to the new
muffler position, while maintaining a ground clearance safety margin compared to the feelers on
the foot-pegs, 3. Aesthetically pleasing position of the cases on the motorcycle, mainly in
relation with the muffler and the seat, and 4. Utilize a three point support/mounting system for
each luggage rack and a cross brace while keeping the rack modifications as simple as possible.
Photo 1 Author's K1300S (left) and K1200S (right) with Givi V35 PLX side cases.
Description of the completed installation and summary of the modifications
The cost of a pair of Givi V35 PLX side cases is about $500 and for the Givi PLX687 side
racks, designed for the BMW F800S, about $200. The weight of each V35 case is about nine
pounds and the recommended load capacity is about 13 pounds for each case. The steel support
racks add about another ten pounds to the motorcycle. Each case holds about 35 liters. With the
V35 cases installed and shut, the maximum width is about 40 inches. The maximum width of
the K1200S at the stock mounted mirrors is about 36 inches. The highest point on the cases is at
the same height as the top of the passenger portion of the stock standard height BMW seat. I
determined by static measurements that the rear of the muffler on the K1200S could be lowered
by several inches and the feeler on the right foot-peg should still touch down first when leaning
the motorcycle over in right turns. I made the same determination for the mounted V35 cases
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early in the design/modification process, that is the feelers on the foot-pegs should touch down
before the bottom of the cases. Subsequent use of the Givi V35 cases for nearly six years and
more than 60k miles have confirmed that there are no issues with ground clearance.
The clearance between the top of the muffler and the bottom of the right side case is about
2-1/4 inches, which is more than on some BMWs with BMW cases. The rear turn signals are
still in the stock location with the luggage racks installed and the V35 cases mounted. In several
locations there is only a few millimeters of clearance between the racks/cases and the turn
signals and rear body panels. Since the passenger foot-pegs cannot be folded up completely
before hitting the front of the cases, they were removed. The passenger foot-pegs could be
retained, but the installation will be somewhat different from that described below and shown in
Photo 2.
Photo 2 Right side rack showing three mounting points, lowered muffler, passenger foot-peg
removed, and two-piece steel flat bar bracket to lower the muffler on my K1200S.
The rear frame of the F800S and K1200S (and K1300S) are similar, thus the same three
support locations were used to mount the luggage racks: 1. under seat frame member rear
support (also used for BMW sport panniers), 2. passenger hand rail (also used for BMW sport
panniers) upper support, and 3. passenger foot-peg frame member lower support. A cross brace
running between the two rear supports was also added. BMW uses a cross brace for their sport
panniers and Givi uses a cross brace on many of their side case racks, but not the PLX687 side
racks. The luggage racks are constructed of ~5/8" diameter painted steel tubing and come with
all the painted steel brackets and nuts and bolts needed to mount them to the frame of the F800S.
Steel brackets were also included for relocating the rear turn signals on the F800S. Custom
brackets were made by the author from half inch diameter mild steel tubing and 1"x1/8" steel flat
bar (details below). Additional 5/16" bolts, 8 millimeter bolts, 6mm bolts, flat washers, lock
washers, hex nuts, and acorn nuts were purchased by the author. Only one MIG weld, which
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was done at a local shop on the left side rack, was required to add a 1/2" steel tubing extension
(details below). No other welding was required, but cutting, bending, grinding the ends,
flattening the ends, and drilling holes was required for the half inch tubing brackets (details
below). Cutting, grinding, and drilling holes was required for the flat bar bracket (details below).
Cutting, some bending, flattening a cut end, and drilling was required for the Givi racks (details
below). Givi supplied "support" parts #2 and #3 were modified by cutting and by drilling an
additional hole (details below). See Appendix for Givi drawing of Givi supplied parts.
Instructions for modifying Givi brackets to fit the K1300S and K1200S – rear support
Start with the rear support by first cutting the Givi supplied "support" bracket part #2
shown just above the ruler in Photo 3. The author cut the cylindrical portion of this Givi
supplied bracket with a hacksaw to a length of 4cm on the end with the nut installed as shown in
Photo 3, but it is suggested to cut it to a length of 3cm. Save the portion that is cut off to make
spacers (details below). One of the 18mm diameter x 24mm cylindrical "spacers" part #15
supplied by Givi is shown in Photo 3. To the right of this Givi part #15 in Photo 3 are 5/16"
stainless steel washers which are used to make up the rest of the spacer needed at the rear
support. These washers will be used to adjust the alignment of the left and right side racks so
that the cases are mounted symmetrically, are parallel with the length of the motorcycle, and
have sufficient clearance at the turns signals and rear bodywork of the K1300S/K1200S.
Photo 3 Modified Givi brackets using Givi parts #2, #3, #5, and #16, 24mm spacer Givi part
#15 (red arrow), and non-Givi bolts, nuts, and washers for the left side rack rear support.
Next, drill a 5/16" diameter hole just above the bend in one of the Givi supplied stamped
steel support brackets part #3 as shown in Photo 4. The red arrow in Photo 4 points to the only
drill hole that needs to be added to this bracket. These stamped steel brackets were intended to
move the rear turn signal lights on the F800S. Photo 3 shows the stamped steel bracket edge on,
whereas Photo 4 shows a side view. Next, using one of the Givi supplied M8x50mm rounded
head cap screws part #5, bolt together the modified stamped steel bracket to the modified bracket
with the shortened cylindrical portion, with a 5mm Givi spacer as shown in Photo 3 and more
clearly in Photo 5. The 5mm spacer shown in Photo 5 is Givi part #16 "spacer" supplied with the
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PLX687 racks and the small end of this spacer fits into the modified Givi part #2.
Photo 4 Modified Givi brackets bolted to under seat frame member for left side rack rear
support – view showing the added hole used for left side rack (red arrow) and the hole for the
cross brace (hole at far left). Bracket in use for ~36k miles when photo was taken.
Photo 5 Modified Givi brackets bolted to under seat frame member for left side rack rear
support – view showing 6mm cap screw bolted to frame and 5mm spacer, Givi part #16.
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Next, using a 6mm hex head cap screw like that shown in Photo 3, an oversize 6mm flat
washer, and lock washer; bolt the modified two-piece Givi rear support bracket to the left side
under seat frame member of the motorcycle as shown in Photos 4, 5, and 6. A washer, not
shown in any photos, needs to be added between the under seat frame member and the modified
two-piece Givi rear support bracket. The internal diameter of this washer needs to be large
enough to fit around the protruding part of the under seat frame where the 6mm cap screw goes.
It is suggested not to bend the stamped steel brackets when aligning the cases, which is what the
author did on his original installation on the left side. Also the condition of these 6mm threads at
the under seat frame members should be checked before starting this project.
Photo 6 Modified Givi brackets bolted to under seat frame member for left side rack rear
support. This view shows a portion of the cross brace with 36k miles of rock chips. The left
side rack and the left case are also shown installed. The arrow points to the end of the 5/16"NC
x 2" long round head hex key cap screw that holds the left side rack to the left side rear support
brackets.
Although modifications to the racks will need to be made as described in the next section
--- upper support below before they can be bolted to the rear support, Photos 2, 6, and 7 show
how the left side rack attaches to the modified rear support brackets. Photo 7 shows the left side
rack bolted to the author's K1300S with about 30mm of cylindrical spacers (= one 24mm spacer
Givi part #15 and six stainless steel 5/16" washers) held by a 5/16" round head hex key cap
screw. This hex key cap screw is also shown in Photo 3 and has a length of about 2". I found
that a 5/16" round head hex key cap screw fits snugger in the round opening in the Givi racks for
the rear support than the similar 8mm cap screws supplied by Givi.
Next, make the same modifications for the rear support brackets for the right side. But see
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instructions in the next section before trying to fit the luggage racks on the motorcycle. Note that
the author used a flat washer and a lock washer on each of the three bolts that are used for the
rear support for each side.
Photo 7 Modified Givi brackets for the rear support bolted to the left side Givi rack showing
the 24mm cylindrical spacer Givi part #15 (red arrow), 5/16 inch "spacer" washers, part of the
cross brace, and part of the left side case.
Instructions for modifying Givi racks to fit the K1300S and K1200S – upper support
The original upper bracket that came bolted to the right side rack is shown in Photo 8
(photo from the Givi PLX687 instructions). Start by removing the plastic cover and unbolt the
Givi upper bracket held by two round head hex key cap screws from each Givi rack. Photos 9
and 10 show the left side rack installed with and without this plastic cover. Next, swap the Givi
upper bracket from the right side rack to left the side rack. This was done because it provides
additional clearance between this upper bracket and the rear bodywork. Note that the extended
portion of the upper bracket remains pointed towards the rear of the motorcycle after swapping.
Next, cut off the Givi upper bracket for the left side rack leaving a length of 6cm as shown in
Photo 11. Note that the end of the upper bracket is aligned with the bolt hole in the pillion
handle when the rack is installed as shown in Photo 11. Using the same two hex head cap
screws, reinstall the swapped and cut down Givi upper bracket on the left side rack as shown in
Photo 11. You may need to bend the swapped and cut down bracket at the weld by a small
amount to get it to bolt back up properly. It is suggested to heat the weld with a propane torch to
put less stress on it when you do this bending, although the author skipped this heating step.
Repeat these steps for the upper Givi bracket for the right side rack.
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Photo 8 Right side rack showing the Givi upper bracket to be removed and swapped with
similar part on the left side rack (photo from Givi PLX687 instructions for BMW F800S).
Photo 9 Left side rack showing plastic cover over bolts for the Givi upper bracket – view
showing left side rack installed on K1300S sans case and seat removed.
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Photo 10 Left side rack sans plastic cover over the bolts for Givi upper bracket – view showing
left side rack installed on K1300S sans case and seat removed. 2013 photo, ~60k miles on racks.
Photo 11 Left side rack upper support showing length to cut the Givi upper bracket = 6cm –
view shows alignment of left side rack and upper bracket with bolt hole in the pillion hand rail.
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The next step is to do a trial fit of the left side rack to the motorcycle in the position shown
in Photo 11 using only the rear support bracket described in the section above. Since the right
side Givi case requires some modification (see details in this section further below), it is
suggested to trial fit the left side first. You will also need to cut off at least some of the lower
portion of the rack which is designed to bolt to the F800S passenger foot peg – skip to the next
section for where to make these cuts for each rack. I recommend that you cover the bodywork
panel shown in Photos 11 and 12 with a towel to avoid scratching it during the trial fitting. As
part of the trial fitting you will also need to install the left side case on the rack to check for
clearance at the turn signal and at the widest portion of the bodywork panel, which is just to the
left of the end of the ruler in Photo 11. The author set a clearance of only about 3mm between
the front of the rack and the bodywork panel as indicated in Photo 12. It is recommended that
the initial clearance at each turn signal and each case be set at 4-6mm as indicated in Photo 13.
After the initial installation and alignment, the author found that the clearance at the turn signals
decreased with what can be described as a break-in period with the cases loaded. With the left
side case installed, check the alignment in all three axis with respect to the motorcycle and adjust
the two-piece rear support bracket position with the three bolts and as needed with washers as
shown in the previous section. Use some kind of support under the case to hold it up during this
adjustment process.
Photo 12 Left side rack showing three mounting points and passenger foot-peg removed.
Arrow points to one of the locations with minimal clearance. There is only about a 3mm gap
between the rack and the front of the rear body panel.
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Photo 13 View of cases mounted and partial view of cross brace from behind. An initial
clearance of 4-6mm is suggested between the ends of the turn signals and the cases.
After aligning and adjusting the position of the left side case and left rack, tighten the three
bolts at the rear support brackets. With the left side rack in the position like that shown in Photo
11, you can make your own measurements to fabricate the bent ½" tubing bracket like
the one shown in Photo 14. The centerline between the two 5/16" diameter holes in this custom
made tubing bracket is about 5cm as shown in Photo 14. To locate the bend for this ½" tubing
bracket so close to the end, the author made the bend in a longer piece of tubing, then cut off the
ends. Tubing benders were used and the outside radius of the ½" mild steel tubing was heated
with a propane torch to facilitate making this type of bent tubing bracket.
After cutting off the excess ½" tubing, the ends were flattened partially with a vice and then
completely flattened by beating with a hammer. The tubing was heated with a propane torch to
facilitate this flattening of the ends. Next, a 5/16" hole in the rack end of the ½" tubing bracket
was drilled as indicated at the bottom of Photo 14. The incomplete ½" tubing bracket was then
installed on the Givi upper bracket in the position shown in Photo 15 and the second 5/16" hole
for the 8mm pillion hand rail hex head bolt was marked. A 5/16" x 3-1/4" hex head cap screw,
two modified brass sink faucet seats, 5/16" spacer washers, and 5/16" nuts as shown to the right
of the ruler in Photo 14 were used to mount the incomplete ½" tubing bracket. The modified
brass sink faucets seats are used to center the 5/16" x 3-1/4" cap screw in the Givi upper bracket.
These sink faucet seats were drilled to 5/16" inside diameter, the outside diameter was ground
and filed to fit the inside diameter of the Givi upper bracket, and the top was ground and filed
flat while leaving a raised lip. One of these modified brass seats is shown installed in Photo 11,
just above the "0cm" on the ruler and another is shown near the bottom right of Photo 14.
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Next, the second 5/16" "marked" hole was drilled in the upper end of the ½" tubing bracket.
To complete the fabrication, the edges of this ½" tubing bracket were ground with a radius and a
wire wheel brush was used to smooth the part. When the finished upper support tubing bracket
is installed, it has a clearance of only about 3mm above the rear body panel as shown in Photo
15. A 5/16" ID spacer can be made, like the one shown in Photos 14 and 15 or you can use all
Photo 14 Custom bent ½" tubing bracket and non-Givi bolts, nuts, spacer, and washers for the
upper support. This side view of the custom made ½" tubing bracket shows about 5cm between
the two 5/16" diameter holes. The arrow points to one of the brass sink faucet seats that was
modified – two required for each side.
washers to bolt the ½ " tubing bracket to the passenger hand rail. The spacer shown was made
from material removed from Givi "support" part #2 in the previous section – rear support. The
washers are used to make alignment adjustments in the vertical axis. The author purchased
round head hex key 8 mm cap screws to attach the upper end of the ½" tubing brackets and cut
the ends of the screws to the proper length. These screws need to use most of the threads in the
pillion hand rail, but not bottom out before they are tight.
Do the same for the upper support for the other side. Next, the author modified the outside
of the right side case at the lower inside corner adjacent to the BMW original muffler support
area of the frame member that holds the passenger foot peg and muffler as shown in Photo 16. I
carefully heated the corner of the case with a propane torch and pressed the soften plastic with a
rounded metal tool. Proceed cautiously when doing this so you don't catch the plastic on fire.
This pressed-in area provides clearance at the original muffler support. This pressed-in area on
the right side case is typically unnoticed because of the location towards the backside of the case
and it had no effect on the function of the case including water sealing at the case gasket. Note
that the left side rack was mounted towards the outside of the muffler bracket in 2011 as shown
in Photo 16, whereas in 2008 it was installed on the inside of this bracket as shown in Photo 2.
The 2011 installation provides more clearance between the front lower corner of the right side
case and the muffler support frame member. With both cases mounted, make alignment
adjustments as needed so that both cases and racks have the same clearances on each side. It is
suggested to use a ruler and make measurements on each side to insure this symmetry within
about 1/16". You can also put a straight edge across the tops of the cases to check that the height
is the same on each side by removing the seat and using the rear frame members as a reference
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point. Also check that the cases are both the same when measured from a front and or rear
reference point. With the cases and racks adjusted and the upper support and rear support
brackets tightened, proceed to the lower support instructions.
Photo 15 Bent ½" tubing bracket for the upper support with ~3 mm clearance at the bodywork.
Photo 16 Lower corner of right side case showing area pressed-in to provide clearance.
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Instructions for modifying Givi racks to fit the K1300S and K1200S – lower support
Photos 17 and 18 show how the lower extension from the left side rack was bent, cut to
length, and installed. A bent piece of ½" tubing was fabricated and welded to this lower
extension and bolted to the left side passenger peg frame member as shown in Photos 17 and 18.
To do the initial installation of the left side rack in the previous section, it is suggested to cut off
only that part of the lower extension that is needed to avoid interference, leaving most of the
lower extension to be used as a lever to facilitate the bending of the lower extension. The Givi
tubing is difficult to bend and the author left several bending marks in the lower extensions,
which can be seen in the photos. Care must be taken when doing this bending so as not to
damage the Givi weld where the lower extension attaches to the rack or bend that part of the rack
that holds the case. The author used a shop vice mounted on a bench attached to the wall to hold
the rack while doing this bending. Using an acetylene torch and heating the tubing would
facilitate this bending, but the author did not have such a torch, thus the bending marks.
Photo 17 Bent portion of left side rack with welded on ½" tubing extension for the lower
support. Passenger foot-peg has been removed. Length of arrow is ~67mm which can be used
to determined where to cut the lower tube on the left side rack and to fabricate the ½" tubing
extension.
After bending the lower extension of the left side rack as described above, cut off the
extension so that it matches the 67mm dimension shown in Photo 17. Next, drill out the
extension of left side rack so that a piece of ½" tubing can be inserted in the end to a depth of
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about 3/4". Drill the end of the extension so that the ½" tubing fits snuggly into it. Remove the
paint from the extension adjacent to where the weld will be made and smooth the end with a wire
wheel. At this point you need to decide if you wish to retain the passenger foot pegs or remove
them as the author did. Note, that the passenger foot pegs will not fold up completely with the
cases installed. The passenger foot pegs could be retained, but the installation of the bent ½"
tubing extension shown in Photo 18 would need to be made to the bottom of the passenger foot
peg frame member, not the inside of it as I did. Next, fabricate a bent ½" tubing extension like
that shown in Photos 17 and 18, so that one end inserts into the drilled out rack extension to a
depth of about 5/8" and the other end is fattened and a 5/16" diameter hole is drilled so that it can
be bolted to the passenger foot-peg frame member. Insert the ½" tubing extension and use
washers to adjust the position of the ½" tubing extension to properly align the left side rack. Do
not weld the ½" tubing extension to the left side rack until you have completed the installation of
the right side rack lower support – discussed further below – and completed the alignment of
both cases.
Photo 18 Bent portion of left side rack with welded on ½" tubing extension for the lower
support. Passenger foot-peg has been removed. Same photo as Photo 12 but shows a close up of
the lower support.
Photo 19 shows how the lower extension from the right side rack was cut to length and
installed at the top of the 1"x1'8" steel flat bar bracket. There is a vice mark on this lower
extension in Photo 19 that occurred while bending the end of the extension after it was cut to
length and after the end had been flattened. The bend will mainly be at the transition between
the flat part and the round part of the lower extension. As described above, care must be taken to
properly hold the rack so as not to damage the Givi weld where the lower extension attaches and
not damage the rack while doing this bending. Heating with a propane torch will facilitate this
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bending. To do the initial installation of the left side rack described in the previous section –
upper support, it is suggested to cut off the lower extension from the right side rack to a length
of 64mm as indicated in Photo 19.
Photo 19 Two flat bar brackets and a ½" tubing triangulation bracket for the lower support as
installed on my K1200S. Length of arrow is ~64mm = length to cut lower extension on the right
side rack = from center line of rack to the end of the flat bar bracket. Same photo as Photo 2 but
shows a close up of the lower support.
Prior to drilling a hole in the flattened end of this extension from the right side rack, the
next step is to fabricate the 1"x 1/8" steel flat bar bracket or brackets that are used to lower the
muffler and attach the right side rack lower support. In the original installation in 2008 two flat
bar brackets were used as shown in Photo 19. Rubber washers and rubber bushings were used in
the 2008 installation so that the muffler was "rubber mounted." BMW revised the muffler and
muffler bracket for the K1300S, so in 2011 I had to make a new lower bracket. I decided to
simplify the lower support to a single steel flat bar bracket as shown in Photos 20 and 21. The
muffler is now mounted using nylon washers to keep from marring the chrome finish on the
BMW muffler bracket. These nylon washers are not shown in Photo 21. The single flat bar
bracket is rubber mounted to the right side frame member using the BMW rubber grommet, large
flat washers, and two large rubber washers as shown/explained in Photos 20 and 21.
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Photo 20 Single flat bar bracket and a ½" tubing triangulation bracket for the lower support as
installed for the right side rack on my K1300S. Givi and non-Givi bolts, nuts, and washers.
Arrow is 53mm.
As shown to the far left of Photo 21 a 5/16" hole was drilled close to the slanted edge at the
bottom of the flat bar bracket so that it will fit and align with the muffler bracket of the K1300S.
As shown in Photo 21 the three 5/16" diameter bolts holes are centered along the width of the
flat bar bracket and the distance between bolts holes are 40mm and 46mm. The key dimension is
the 4cm between the lower hole and the middle hole. This 4cm dimension sets the distance that
the muffler is lowered. Therefore for this design, the muffler was lowered about 1.5 inches at the
support point as shown in Photos 19 and 20. For the correct distance between the top hole and
middle hole of the flat bar bracket, you should mount the bracket on the motorcycle and mark it.
You will also need to bend the flattened part of rack extension to adjust the fit at the rear support
as described above. After drilling the three holes in the flat bar bracket it is suggested to mount
it to the motorcycle and then mark the hole on the corresponding rack extension. In the author's
case, the centerline of the rack to the center of the 5/16" hex head cap screw holding the rack to
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the lower support bracket in Photo 20 was 53mm. The last step in fabrication of the flat bar
bracket was to grind a radius in the corners of the bracket and to smooth the edges and bolt holes
with a wire wheel. The ½" steel tubing triangulation bracket that I fabricated for the right side
lower support could be considered to be optional, since its only functional purpose is to
strengthen the lower support frame member. Photos 19 and 20 show this triangulation bracket
mounted and Photo 21 shows a side view of this bracket above a ruler. As part of the final
alignment of both racks and cases, you may need to add a washer = spacer between the flattened
and drilled portion of the right side rack extension and the flat bar bracket. Note that once the
left side is welded there is less adjustment available on that side at the lower support.
Photo 21 One flat bar bracket and a ½" tubing triangulation bracket for the lower support for
the right side of my K1300S. Givi and non-Givi nuts, bolts, and washers. Nylon washers used at
muffler bolt not shown in this photo. Two rubber washers to match large 5/16" flat washer also
not shown in this photo. Only one large 5/16" flat washer is shown in this photo, two are used.
Arrows are 40mm and 46 mm. The 40mm sets the distance the muffler is lowered.
Instructions for cross brace for the modified Givi racks for the K1300S and K1200S
The next step is to make the final adjustments in the two racks so that they are in correct
alignment with the motorcycle and both sides are mounted symmetrically. Small adjustments
can be made by adding or removing washers at various locations as previously described. After
completing these adjustments and prior to welding the ½" tubing extension to the left side rack,
the next step is to fabricate and install a cross brace. The two ends of the installed ½" diameter
steel tubing cross brace are shown from a rear viewpoint in Photo 13, just below the rear turn
signals. A ¼" all-thread rod is installed through the cross brace and through the far left hole in
the upper support bracket shown in Photo 4. This bracket which is Givi part #3 (see Appendix)
already had this hole in it. Acorn nuts are installed at the ends of the ¼" all-tread as shown in
Photos 13 and 7. A stainless steel #12 finishing washer installed at the each end of the tubing
was used to center the 1/4" all-tread rod as shown in Photo 6. The lip of the finishing washer just
fits around the end of the cross brace ½" tubing as shown in Photo 6. Knowing how its installed
and its purpose, measure the length of tubing needed and cut a piece to that length. The ½"
tubing for the author's installation was 9-3/8" long. Next, file the ends of the tubing flat and
smooth the edges with a wire wheel. The cadmium plated ¼" all-tread rod was cut to a length
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about ten inches. A stainless steel lock washer and a stainless steel flat washer were installed
under each stainless steel acorn nut at each end as shown in Photo 7.
Instructions for welding, painting, & final assembly of the modified Givi racks
for the K1300S and K1200S
After completing the alignment adjustment of both racks and the installation of the cross
brace as described above, mark the position (depth and angle of rotation) of the ½" tubing
extension in the left side rack at the lower support. This extension and the one weld that needs
to be made were previously described and shown in Photos 17 and 18. Next, remove the left side
rack from the motorcycle leaving the upper and rear support brackets in place. Clean and
degrease the area of the rack and the ½" tubing extension where the weld will be made. Take
care during this cleaning not to remove your position marks. Remove the four rubber grommets
and plastic cover at the upper support from the rack prior to welding. Next, weld the extension
to the left side rack in the marked position. The author had the welding done at a local car shop
and they made a full circumference MIG weld. Take care not to get water inside the rack
through the grommet holes if it is cooled with water after welding.
Prior to painting the left side rack adjacent to the lower support, it is suggested to reinstall
it on the motorcycle and confirm that the ½"extension was welded correctly. Next, replace the
four rubber grommets and plastic cover to the left side rack, assuming that you will only paint
that portion of the rack adjacent to the welded/bent area. If you do a test ride at this point, prior
to painting, make sure all bolts are tightened properly. As a precaution take suitable tools and a
few extra nuts and bolts with you. Next, remove both racks and all of the brackets used to hold
the racks in order to paint them. Note the positions of spacer washers and other adjustable parts
and/or take photos to help facilitate the final assembly. The author choice not to paint most of
the stainless steel nuts, washers, and bolts.
During all of the previous work described above the author did not use Locktight on any of
the treads. But for the final assembly I used Locktight on many of the bolt treads. I especially
recommend that Locktight be used on the cap screws that go into the pillion hand rails at the
upper support and the cap screws that go into the under seat frame at the rear support. Take
care not to over-tighten these fasteners, otherwise you could end up having to replace some
BMW parts. I also used self-locking nuts, lock washers, and in a few places double nuts. As a
precaution it is suggested to carry tools needed to tightened any fasteners that might loosen
during the first several hundred miles after the installation of the racks. During this period,
frequently check that all of the fasteners are still tight by trying to turn them with your fingers.
For extended trips it is suggested to take appropriate tools with you and a few spare nuts, in case
they are needed.
Postscript & testing of Givi V35 PLX side luggage on my K1200S and K1300S
I did the design work and original installation in the summer of 2008 on my K2100S.
During initial testing for the first couple hundred miles and prior to painting, the only bolt that
loosened was one of the long bolts in the upper support – see Photo 2. The solution was use a
longer 5/16" x 3-1/4" hex head cap screw, retighten to a higher torque, add an acorn nut (in
addition to the hex nut), and a new lock washer as shown in Photo 2. It is suggested that you
frequently check all of the fasteners for looseness during the first thousand miles after the
installation. On my first long trip out of town with the new cases I experienced some
settling/break-in at the upper and rear supports, which caused the clearance gap at the rear of the
cases and the turn signals to close up as mentioned in the instructions. To address this issue I
suggested to set the initial clearance between the cases and the turn signals at 4-6mm, as
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described in the instructions and shown in Photo 13. It is further suggested to load the cases to
their maximum weight capacity of about 13 pounds for each case for the first thousand miles.
Then recheck this clearance and re-adjust the alignment of the cases after this break-in period.
Even if you make no alignment adjustments following this thousand mile break-in period, it is
suggested that you re-torque and/or check the torque on every fastener on the racks.
Following my first out of town trip on my K1200S, I purchased the Givi liners for my V35
cases. I found that the liners greatly simplified packing and unpacking. The loss of any packing
volume by the liners themselves is more than made up for by improved packing efficiency and
convenience. When I transferred the modified racks and V35cases to my K1300S in 2011, I had
about 36k miles on the cases and racks with no issues. You can see what 36k miles of rock chips
looks like on the rear cross brace in Photo 6. As described in the instructions I had to make a
new flat bar bracket to match the revised BMW muffler bracket on my K1300S. Going to single
flat bar bracket at the lower support as shown in Photo 20 has not caused any issues. I now have
an additional trouble-free 24k miles on the V35 cases and racks on my K1300S. As indicated by
various photos I painted the silver V35 case panels with red polyurethane and clear coat to match
the BMW red on my K1300S.
The plastic Givi covers over the Givi upper support brackets – shown in Photo 9 – are
retained in place only by friction. I still have the original ones and they have never come off
on their own, even during washing. I replaced the rubber pads on the racks with new ones at
the time I transferred them to my K1300S. There are four of these rubber pads on each rack –
See photos 2 and 12. These four rubber pads along with the five Givi mounting points on each
side provide a very secure fit of the V35 cases to the steel racks. With three mounting points
on each side and a cross brace, the luggage racks are very securely attached to the rear frame of
the K1200S/K1300S. Partly due to the rounded shape at the front of the cases, partly due the
sloping angle at which they are installed, and probably partly because they are mounted about
as far forward and as low as practical, my K1200S/K1300S is very stable at speed with the
racks and V35 cases installed. The maximum recommended speed by Givi for fully loaded
cases is 120 km/h. BMW recommends ≤112 MPH with the BMW sport panniers, per the
K1200S owner's manual. Suffice it to say, I've tested this installation with fully loaded cases at
speeds that you would not maintain for long on public roads in the USA.
Since publishing a less detailed article on this subject in the May 2009 BMW MOA Owner's
News magazine I have been contacted by about 20 individuals that had questions about this
custom installation of Givi V35 cases on my K1200S/K1300S. Of these 20, only two or three
indicated they planned to do something similar to what I did. But for various reasons they never
did, as far as I know. With one exception, I have never seen in-person a K1200S or K1300S with
any side luggage other than the BMW sport panniers. The one exception was a K1200S at the
2010 MOA National Rally. The owner had lowered the muffler and mounted 1998-2005
K1200RS style BMW cases. He had cut the rear body panels to provide clearance for the
cases/mounts. For many of the individuals that have contacted me, they had not seen the May
2009 article. After learning the extent of the modifications needed to install the Givi PLX687
racks, and possibly the lack of detailed written instructions, they did not pursue my design.
Because my design does not leave much room for a pillion rider's feet/shoes when the cases
are installed and because the passenger foot pegs cannot be folded up completely before hitting
the front of the cases, I decided to remove these foot pegs. This was an issue for some of the
riders that contacted me about my design. Note that with only minor modifications to these
instructions, the passenger foot-pegs could be retained and with the V35 cases removed normal
foot/shoe support for a passenger could be provided. I suspect that the reason that my design or
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something similar to it has not been adopted commercially for the K1200S or K1300S by Givi or
others is that they will not consider to lower the muffler, probably because of liability issues. If
you have any concerns about the lowered muffler dragging or touching down before the feeler on
the foot pegs, understand that the BMW K1200GT and the K1300GT have an even lower
muffler position than the one used in my design here -- ditto the BMW side cases for the
K1200GT/K1300GT. As shown in photos above and again in Photo 22, lowering the muffler is
the key to this custom installation, which then allows the contoured shape of the Givi V35
luggage to closely fit the rear body panels of the K1200S/K1300S and other parts such as the
rear turn signals. As for the looks of these Givi side cases on the K1300S and K1200S – you be
the judge!
Photo 22 Author's K1300S in Luckenbach, TX, Dec. 2011.
Harry Burney is a retired chemical engineer. He worked for Dow Chemical in process research
for 32 years. He is active in Lions Club and in the San Antonio BMW Riders Association. He
has ridden motorcycles since 1971 and BMW's since 1999. The author can be contacted via this
website for additional information on this article.
© H. S. Burney, Jr. Sept. 2013
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Appendix Givi PLX687 racks for BMW F800S – Givi supplied parts list
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