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CrazyBiker · 08-19-2008, 01:39 AM

Use the plastic washers as described in the manual and install the smaller rack as instructed. Now trying to get all the bolts in place is a bitch mainly due to the welded counternuts in the part that attaches the upper portion of the grab rails. I had to bend one a little to get it to align right. The tolerances are extremely tight and I had to try multiple times loosening/tightening screws to get it right. Don’t tighten all the screws first. Tighten the lower bolts enough so that the grab rail compresses to the required alignment for the top screws but loose enough that you can slide the rack back and forth. Infact as I was tightening I could hear the welds on the counternuts snapping off; only after that the screws aligned with the counternuts properly. But since they will keep rotating while tightening, I pushed in different allen keys to arrest their rotation. Now install the screws for the top rack to secure it tightly to the lower rack. This is how it looks after install.
IMG_3260.JPG IMG_3264.JPG IMG_3263.JPG

Now comes the simple part. Follow the manual for the rest. You’ll only need the shorter screws from the supplied kit from the top case.

IMG_3271.JPG IMG_3273.JPG

08-19-2008, 01:39 AM	#3 (permalink)
CrazyBiker SuperBike Champion Join Date: Jun 2007 Location: Nashville, TN Age: 27 Posts: 2,364 Casino Cash: $62743 Sportbike: 07 Black FZ1, 06 FZ6 Converted to newer styling - Black/Blue	Use the plastic washers as described in the manual and install the smaller rack as instructed. Now trying to get all the bolts in place is a bitch mainly due to the welded counternuts in the part that attaches the upper portion of the grab rails. I had to bend one a little to get it to align right. The tolerances are extremely tight and I had to try multiple times loosening/tightening screws to get it right. Don’t tighten all the screws first. Tighten the lower bolts enough so that the grab rail compresses to the required alignment for the top screws but loose enough that you can slide the rack back and forth. Infact as I was tightening I could hear the welds on the counternuts snapping off; only after that the screws aligned with the counternuts properly. But since they will keep rotating while tightening, I pushed in different allen keys to arrest their rotation. Now install the screws for the top rack to secure it tightly to the lower rack. This is how it looks after install. IMG_3260.JPG IMG_3264.JPG IMG_3263.JPG Now comes the simple part. Follow the manual for the rest. You’ll only need the shorter screws from the supplied kit from the top case. IMG_3271.JPG IMG_3273.JPG __________________ 07 Raven FZ1 (May 06 2009) Micron Full System\|O2 Elim\|Lars Airbox Mod\|Ivan's FCE\|BMC\|CopperDawg Flies\|HEL SS Lines,Speed Bleeders\|ASV Black Shorties\|Rizoma Rearsets\|Sargent/Corbin Rider/Pillion\|MRA Vario\|Throttlemiester\|Satan666 Highway Pegs\|Reverse Retro Mirrors\|Symtec Heated Grips\|Marine Powerlet\|Integrated Taillight\|Arrow Signals\|T-Rex Frame,Crashbobbins F/R Axle Sliders\|Targa FE\|Power Bronze Rear Fender 06 Black FZ6:(July 29 2007) R6S Forks,Speedbleeders,SS Lines,HH Sintered Brake Pads\|15T,Speedohealer v3\|Laser Extreme Quad,-CAT,K&N,PC3\|Puig Light Smoke Racing\|06 FZ1 Bar\|TS Seat\|T-Rex Sliders,Axle Crash Bobbins\|FAZR6 FE\|Powerlet\|Dual Headlight Mod (Xenon Super White)\|F/R Arrow Signals\|Pod Light Mod\|Fiamm HB Lo Tone\|Reflective Decals on Frame\|Universal RAM Mount\|BT-016 Last edited by CrazyBiker : 08-19-2008 at 02:31 AM.