Givi Pannier Mounts - Kawasaki KLR 650 Forum
Gadgets & Gizmos Discussion on the latest "toys" to enhance the adventure.

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  • 1 Post By frostbitevinnie
  • 1 Post By Jack.Moorhead
 
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post #1 of 6 Old 05-06-2016, 05:43 PM Thread Starter
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Join Date: Oct 2015
Location: St. Cloud, MN
Posts: 259
Givi Pannier Mounts

I have happy trail side racks but I really want to be able to mount my givi bags on the KLR. I could buy a set for gen 2 but apparently they don't make them for the gen 1 anymore. So the solution, as always, is to make some racks myself.

My first task was to accurately measure the mount tab locations. I have not been able to find these dimensions on the web so I had to do some accurate measuring. Figured that all out and I have my givi mount kit from white horse gear for $28 now to drawing it all out, choosing material, programming, testing program, and finally machining.

I was going to go with 3/16 A36 plate but found some nice 3/16 stainless that was perfect cept for a little trimming. First rough drawn out on a steel plate with rough dimensions.


Do more calculations, write a program, and test program on an old scrap plate. Also determine clamp placement.


Program proved out good but I'm not happy with my dimensions. I wanted to tighten up the radius around the holes so back to the drawing board, or this case cnc control panel. Done!

Now to cut these suckers out!
Probe block X, Y, Z.


Drill and tap for hold downs. None of the holes suited my needs so I made the block more resemble swiss cheese.




Clamp her down!


Hole pattern looks good.


Machining!

'01 KLR 650, '09 Suzuki DL650, '08 Suzuki Bandit 1250, '16 CRF1000L, '09 KLX 250s
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post #2 of 6 Old 05-06-2016, 05:49 PM Thread Starter
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Machining done!


Gotta mount them to this!


Clamped for drilling.


Drilled!


Mounted!


And the bag fits right on!

'01 KLR 650, '09 Suzuki DL650, '08 Suzuki Bandit 1250, '16 CRF1000L, '09 KLX 250s
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post #3 of 6 Old 05-06-2016, 05:53 PM Thread Starter
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If anyone is interested in the dimensions for fitting givi bags I will freely share them. If you want a copy of the heidenhein txt. program to take to your favorite local machinists I will also happily and freely share that. Heck, lets just post it here now!

0 BEGIN PGM RACKS INCH
1 * - .75 CARB DRILL
2 CALL PGM TNC:\SUBS\HIPOS
3 CYCL DEF 304 INDEX BOTH JOINTS ~
Q391=+90 ;Rear Joint Angle ~
Q392=+0 ;Front Joint Angle
4 TOOL CALL 40 Y S1200
5 CALL PGM TNC:\SUBS\HIPOS
6 CYCL DEF 304 INDEX BOTH JOINTS ~
Q391=+270 ;Rear Joint Angle ~
Q392=-90 ;Front Joint Angle
7 CYCL DEF 307 HEAD OFFSET TRANSFER
8 L Y+10 F MAX M3
9 L X-4 Z-4.5 F MAX
10 CYCL DEF 205 UNIVERSAL PECKING ~
Q200=0.1 ;SET-UP CLEARANCE ~
Q201=-0.6 ;DEPTH ~
Q206=100 ;FEED RATE FOR PLNGNG ~
Q202=0.6 ;PLUNGING DEPTH ~
Q203=+0 ;SURFACE COORDINATE ~
Q204=2 ;2ND SET-UP CLEARANCE ~
Q212=0 ;DECREMENT ~
Q205=0 ;MIN. PLUNGING DEPTH ~
Q258=0.01 ;UPPER ADV STOP DIST ~
Q259=0.01 ;LOWER ADV STOP DIST ~
Q257=0.2 ;DEPTH FOR CHIP BRKNG ~
Q256=0.01 ;DIST FOR CHIP BRKNG ~
Q211=0 ;DWELL TIME AT DEPTH
11 CYCL CALL M7
12 L X-9 F MAX M99
13 L Y+10 F MAX
14 STOP
15 * - .228 DRILL
16 CALL PGM TNC:\SUBS\HIPOS
17 CYCL DEF 304 INDEX BOTH JOINTS ~
Q391=+90 ;Rear Joint Angle ~
Q392=+0 ;Front Joint Angle
18 TOOL CALL 24 Y S2000
19 CALL PGM TNC:\SUBS\HIPOS
20 CYCL DEF 304 INDEX BOTH JOINTS ~
Q391=+270 ;Rear Joint Angle ~
Q392=-90 ;Front Joint Angle
21 CYCL DEF 307 HEAD OFFSET TRANSFER
22 L X-5.99 Z-9.545 Y+5 F MAX M3
23 L M7
24 CYCL DEF 203 UNIVERSAL DRILLING ~
Q200=0.1 ;SET-UP CLEARANCE ~
Q201=-0.5 ;DEPTH ~
Q206=80 ;FEED RATE FOR PLNGNG ~
Q202=0.8 ;PLUNGING DEPTH ~
Q210=0 ;DWELL TIME AT TOP ~
Q203=+0 ;SURFACE COORDINATE ~
Q204=3 ;2ND SET-UP CLEARANCE ~
Q212=0 ;DECREMENT ~
Q213=0 ;NR OF BREAKS ~
Q205=0 ;MIN. PLUNGING DEPTH ~
Q211=0 ;DWELL TIME AT DEPTH ~
Q208=1200 ;RETRACTION FEED RATE ~
Q256=0.01 ;DIST FOR CHIP BRKNG
25 CYCL CALL
26 L X-7.01 Z-9.545 F MAX M89
27 L X-10.25 Z-8.625 F MAX
28 L X-2.5 F MAX
29 L X-1.3 Z-7.5 F MAX
30 L X-1.3 Z-2 F MAX
31 L X-2.5 Z-0.375 F MAX
32 L X-2.05 Z-1.06 F MAX
33 L X-10.5 Z-0.375 F MAX
34 L X-10.95 Z-1.06 F MAX
35 L X-11.7 Z-2 F MAX
36 L Z-7.5 X-11.7 F MAX M99
37 L Y+10 F MAX M5 M9
38 L Y+10 F MAX
39 L Z+0 F MAX M91
40 * - .421 DRILL
41 CALL PGM TNC:\SUBS\HIPOS
42 CYCL DEF 304 INDEX BOTH JOINTS ~
Q391=+90 ;Rear Joint Angle ~
Q392=+0 ;Front Joint Angle
43 TOOL CALL 20 Y S1800
44 CALL PGM TNC:\SUBS\HIPOS
45 CYCL DEF 304 INDEX BOTH JOINTS ~
Q391=+270 ;Rear Joint Angle ~
Q392=-90 ;Front Joint Angle
46 CYCL DEF 307 HEAD OFFSET TRANSFER
47 L X-5.5 Z-7.937 Y+5 F MAX M3
48 CYCL DEF 205 UNIVERSAL PECKING ~
Q200=0.1 ;SET-UP CLEARANCE ~
Q201=-0.7 ;DEPTH ~
Q206=80 ;FEED RATE FOR PLNGNG ~
Q202=0.8 ;PLUNGING DEPTH ~
Q203=+0 ;SURFACE COORDINATE ~
Q204=3 ;2ND SET-UP CLEARANCE ~
Q212=0 ;DECREMENT ~
Q205=0 ;MIN. PLUNGING DEPTH ~
Q258=0.01 ;UPPER ADV STOP DIST ~
Q259=0.01 ;LOWER ADV STOP DIST ~
Q257=0.2 ;DEPTH FOR CHIP BRKNG ~
Q256=0.01 ;DIST FOR CHIP BRKNG ~
Q211=0 ;DWELL TIME AT DEPTH
49 CYCL CALL M7
50 L X-7.25 Z-7.937 F MAX M3 M99
51 L Y+10 F MAX M9
52 ;
53 * - .5 CARB RGH
54 TOOL DEF 0
55 CALL PGM TNC:\SUBS\HIPOS
56 CYCL DEF 304 INDEX BOTH JOINTS ~
Q391=+90 ;Rear Joint Angle ~
Q392=+0 ;Front Joint Angle
57 TOOL CALL 0 Z S1800
58 TOOL CALL 116 Y S1800
59 CALL PGM TNC:\SUBS\HIPOS
60 CYCL DEF 304 INDEX BOTH JOINTS ~
Q391=+270 ;Rear Joint Angle ~
Q392=-90 ;Front Joint Angle
61 CYCL DEF 307 HEAD OFFSET TRANSFER
62 L Y-47 F MAX M91
63 STOP ; PUT IN EM
64 * - PLATE OUTSIDE
65 ;
66 L Y+5 F MAX M3
67 L X-5.3 Y+5 Z-10.5 R0 F MAX M3
68 L X-5.75 Z-10.5 Y+0.1 RL F900
69 L Y-0.4 F100 M7
70 L Z-9 F100
71 L X-2.25 F100
72 ;
73 CC X-2.25 Z-6.75
74 C X+0 Z-6.75 DR- RL F100
75 ;
76 ; HORSE SHOE CLAMP
77 L Y+5 F MAX
78 L Z-2.25 RL F MAX
79 L Y-0.4 RL F500
80 L Z-2.25 RL F100
81 CC Z-2.25 X-2.25
82 C X-2.25 Z+0 DR- RL F100
83 ;
84 ; BESSEY CLAMP
85 L Y+5 F MAX
86 L X-10.75 Z+0 RL F MAX
87 L Y-0.4 RL F500
88 L X-10.75 Z+0 RL F100
89 CC X-10.75 Z-2.25
90 C X-13 Z-2.25 DR- RL F100
91 ;
92 ; HORSE SHOE CLAMP
93 L Y+5 F MAX
94 L X-13 Z-6.75 RL F MAX
95 L Y-0.4 RL F500
96 ;
97 L X-13 Z-6.75 RL F100
98 CC X-10.75 Z-6.75
99 C X-10.75 Z-9 DR- RL F100
100 L X-7.25 Z-9 RL F100
101 L Z-10.5 RL F100
102 L Y+5 R0 F MAX
103 ;
104 * - PLATE INSIDE
105 L Y+5 R0 F MAX
106 L X-5.5 Z-7.937 R0 F MAX M3
107 L Y+0.1 F900
108 L Y-0.4 F300
109 L Z-1.06 F100
110 L X-2.8 F100
111 ;
112 CC X-2.05 Z-1.06
113 C X-2.05 Z-1.81 DR- F100
114 L X-2.05 F100
115 L Z-2 F100
116 ;
117 CC X-1.3 Z-2
118 C X-1.3 Z-2.75 DR- F100
119 L X-1.062 F100
120 ;
121 L Z-6.75 F100
122 L X-1.3 Z-6.75 F100
123 CC X-1.3 Z-7.5
124 C X-2.05 Z-7.5 DR- F100
125 L Z-7.937 F100
126 L X-5.5 F100
127 L Y+5 F MAX
128 ;
129 L X-7.25 Z-7.937 F MAX
130 L Y+0.1 F900
131 L Y-0.4 F300
132 L X-10.95 F100
133 ;
134 L Z-7.5 F100
135 CC X-11.7 Z-7.5
136 C X-11.7 Z-6.75 DR- F100
137 L X-11.937 F100
138 L Z-2.75 F100
139 ;
140 L X-11.7 F100
141 CC X-11.7 Z-2
142 C X-10.95 Z-2 DR- F100
143 L Z-1.81 F100
144 ;
145 L X-10.95 F100
146 CC X-10.95 Z-1.06
147 C X-10.2 Z-1.06 DR- F100
148 ;
149 L Z-1.06 F100
150 L X-7.25 F100
151 L Z-7.937 F100
152 L Y+5 F MAX
153 L Y+20 F MAX M5 M9
154 L Z+0 F MAX M91
155 L M2
156 END PGM RACKS INCH


ENJOY!
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'01 KLR 650, '09 Suzuki DL650, '08 Suzuki Bandit 1250, '16 CRF1000L, '09 KLX 250s
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post #4 of 6 Old 06-24-2016, 09:27 AM
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Well, my friend, you have outdone yourself. Thats far above my level. Countersunk allen bolts? Flush bolts are a thing of beauty.
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post #5 of 6 Old 06-24-2016, 07:09 PM
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Excellent thread with outstanding photos. It is threads like this that makes me tell all my friends about the quality of the website and membership.
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2009 Kawasaki KLR 650

always tinkering!
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post #6 of 6 Old 06-24-2016, 11:29 PM Thread Starter
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Location: St. Cloud, MN
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Thanks fellas and I'm glad to be able to contribute from my patch of experience. Y'all have skills that I don't so we all learn from each other just a bit here and there.

'01 KLR 650, '09 Suzuki DL650, '08 Suzuki Bandit 1250, '16 CRF1000L, '09 KLX 250s
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