Here we have an installation of the SW-Motech sideracks
for the Suzuki DL1000
First, keep in mind that installing your sidecase racks BEFORE installing a topcase rack (either the SW-MOTECH Alu-Rack or GIVI E528 topcase mounting plate) will make your life simpler. Also, DO NOT tighten the siderack mounting point bolts until all eight mounting points have been installed on the motorcycle.
Start by getting together the required toolkit:
o 6mm allen key
o 10mm, 12mm, and 13mm socket wrench
o Philips head and flat head screwdrivers
o Drill with 1/4" and 1/2" drill bits
(1) Take inventory of your parts, comparing the contents of your package to the parts list in the installation diagram. Match up the bolts to the appropriate washers and nuts as shown.
(2) Take inventory of your parts, comparing the contents of your package to the parts list in the installation diagram. Match up the bolts to the appropriate washers and nuts as shown. Kind like a smiley face, huh?
(3) Remove the seat from the motorcycle, then remove the four stock bolts securing the luggage rack to the motorcycle. Place the Mo-tech crossbar under the rear of the luggage rack and assemble with the included spacers and washers as shown in the installation diagram. The notches in the crossbar should face the rear of the motorcycle, and the mounting points should point down toward the floor. Next, assemble the 2 mounting tabs that attach to the forward arms of the luggage rack. Again, the notches in the mounting tabs should point to the rear of the motorcycle, and the mounting tabs should point down toward the floor. Do not fully tighten the four replacement bolts; you'll need to adjust the angles of the forward arm mounting points once installation is complete.
(4) Bolt the mounting tab onto the top hole in the rear footpeg mount as shown in the installation diagram. Do not fully tighten the two mounting tab bolts; you'll need to adjust the angles of these mounting tabs once installation is complete.
(5) Remove the license plate from the license plate bracket using the Flathead screwdriver and pliers.
(6) Remove the license plate bracket from the rear fender using the Philips head screwdriver and 10mm socket wrench.
(7) Place the rack's rear crossbar over the raised portion that the license plate bracket attaches to. The mounting tabs on either end of the crossbar should be pointing toward the front of the motorcycle (see picture).
In 2002 versions of this product such as the one shown, you'll notice that the original license plate bracket holes on the U.S. bike's fender do not match the holes on the rear crossbar, which was developed for European license plate hole patterns. Consequently, those installing early versions of this kit will have to drill two pairs of holes in the U.S. bike's fender. Later (2004) versions of the rear crossbar are predrilled for both European and U.S. license plates, so no drilling is required. If you have a kit with the revised crossbar, skip all this drilling stuff!
For those that are less lucky, the first pair of fender holes will be drilled through the outermost pair of holes in the crossbar; these will be used to mount the crossbar to the fender. The second pair of fender holes will be drilled through the innermost pair of holes in the crossbar; these will be used to make room for the nuts attaching the license plate bracket to the crossbar.
(8) Using the included quicklocks, attach the sidecase racks to the motorcycle using the six installed mounting points. You can then position the crossbar on the rear fender by attaching it to the sidecase racks using a pair of quicklocks (see picture). Make sure the crossbar is centered on the fender. Using a magic marker or centerpunch, mark the locations of the 1st, 3rd, 4th, and 6th holes in the crossbar.
(9) Drill a 1/4" hole through the fender at the guide marks for crossbar holes #1 and #6 (see picture). After the holes have been drilled, attach the crossbar to the fender using the included mounting bolts to make sure the crossbar aligns with the fender properly. DO NOT tighten the crossbar mounting hardware, as the crossbar must be removed during the next step of installation. Tighten the mounting bolts for the luggage rack mounting points and rear footpeg mounting points.
(10) With the crossbar in place, check your guide marks for crossbar holes #3 and #4. Remove the crossbar from the rear fender and drill a 1/2" hole at the guidemarks for crossbar holes #3 and #4. These holes make room for the nuts used to attach the license plate mounting bracket to the rear crossbar, as noted in the next step.
(11) The stock license plate mounting bracket has a reflector at each end. These reflectors are originally at a 90-degree angle to the license plate mounting bracket. In order to make room for the rear crossbar, these reflectors must be bent outward by about 45-degrees (see picture). Using two sets of vice grips or pliers makes this job easy; make sure you wrap the bracket with a cloth while bending it so that your tools don't damage the bracket's finish.
(12) Center the license plate mounting bracket over the rear crossbar and clamp them together (it may be necessary to use cloth in the clamp to prevent damage to the painted finish of the parts). If your reflectors were bent properly in step 10, they should not contact the mounting points at the ends of the crossbar. Using a magic marker or centerpunch, mark the locations of the 3rd and 4th holes in the crossbar on the license plate mounting bracket. Drill a 1/4" hole through the guide marks on the license plate mounting bracket.
(13) Bolt the rear crossbar onto the license plate mounting bracket. Use the original hardware to attach the license plate mounting bracket to the rear crossbar as shown (Remember, measure twice, drill once; avoid drilling the extra holes pictured below).
(14) Bolt the rear crossbar/license plate mounting bracket assembly onto the fender using the bolts, nuts and washers provided by SW-MOTECH. Attach the sidecase racks to all mounting points on the bike using the included quicklocks. After making sure everything fits properly, tighten all bolts and nuts at all mounting points.
(15) Re-attach the license plate to the license plate mounting bracket. If you got this far, you don't need any help with this final step. Go get a frosty beverage of your choice and admire your craftsmanship.