|06-03-2007, 09:22 PM||#1|
Joined: Jun 2006
Happy trails Aluminum Panniers install on KLR650
Enclosed is a review and walk-thru install of the "Happy-Trails" Brand Aluminum Pannier Boxes. They produce over 6x different sizes which could fit the KLR650. I installed the second to smallest. They are the Owyhee style 7.5 width x 14 height x 16 length for a total volume of 1,680 in3 or 27.5 liters or 7.3 gallons each. The intent of the boxes are to provide sufficient secure, waterproof transport storage. I ordered the "no finish" option. My previous luggage system consisted of the Ranger style "dirtbagz" soft bags. My criteria for the panniers was:
1. Ability to still carry passenger.
2. Not effect tail view of turn signals
3. Not sticking out too far
4. Secure and lockable
6. More carry than dirt bagz
7. Small drag hit
8 removable from bike
the companies web site is here:
boxes as delivered.
latch mechanism. Accepts a pad lock
lift the latch
unhook from lid
unhook opposite side and lift top
top opens outboard on bike. Top rests on box
welded corner of the 6061 Aluminum
close up of weld
inside "canyon" cut
top rubber lid gasket
gage at .080 inch. Standard size.
outside width at 7.5 inch
lid width at 8 inch. Note "tie-downs" included on lid
length at 16 inches. Next size available at 18 inches
height at 14 inches
canyon cut shown
1.5 inch taper
remove helmet lock. Will need to relocate this later
ready to mount on racks from KLR650.com Studabaker brand. Fit like a glove
attach "puck" system
gage of bracket
mark first hole
like so. Do inside of pannier also
finish 3x holes totals to attach bracket
move fore-aft to find sweet spot for passenger to reach pegs and opens without hitting turn signals
mark thru existing rack threaded attach holes
add a puck....pucky! Hehehe
attach opposite side
enhances look of bike, but that of course is a truly secondary consideration! Hehehe
just the right size
new bike width = 34.5 inches
decals that were delivered with boxes
like this one
only used "trail" from the happy-trails.com
trimmed and tossed the other text
1. Love the boxes
2. Just the right size
3. Good for road trips
4. No real handling or drag issues
5. Stable and secure.
6. Wifey can still ride without box removal
7. Easy on easy off
Now for a keyless lock system
Enclosed is a step by step walk thru for the installation of "keyless" pannier locks. The locks will be installed on Happy Trails aluminum panniers on a KLR650. The intent of the locks are:
1. Provide keyless permanent locking system
2. Detour thieves with high profile lock
3. Easy open/close
4. One hand with or without gloves operation
5. No locks to mess with
6. Weatherproof locking mechanism
panniers to lock
Lock to install
back side of packaging
need to shim up .25 inch for latch to catch on pannier lever, use 2x .125 inch aluminum straps as a shim.
lock is 4 inches in length by 2 inches in width. A tad big but will work.
will fit about here
with latch engaged
Next to normal lock
weight ~ 10 oz
lock ~ 10 oz
planform view of shim
tamper-proof high strength 95,000 psi shear strength 3/16 High Shear Hi-loc.
allen key recess will ease installation, keep pin from spinning!
align holes and drill shim
de-burr holes with piloted 100 degree countersink cutter. Only de-burr not countersink
check hole alignment. Use drill press to prep holes for fasteners
align lock on pannier
square the lock up
mark and drill. Need to hand drill. Wont fit in drill press
need self locking 3/16 nut
ready for install
check latch has free play
one down, 3x to go!
on the bike
1. Met expectations
2. Can and did change combination to my own liking. Default was 0000. Now it is _ _ _ _. Hehehe
3. Truly one hand operation.
4. Nothing is totally secure, but this offers more piece of mind
5. In summary a keeper!
|06-03-2007, 09:27 PM||#2|
Joined: Jun 2006
Few more pictures:
front left 1/4 view...Notice the sweet seat on this bike
front right 1/4 view...notice LED auxillary lights and exhaust armor
rear right 3/4 view
rear view...notice the keyless pannier locks
let 3/4 view notice the custom rear splash fender
klm4755 screwed with this post 06-03-2007 at 09:33 PM
|06-03-2007, 09:49 PM||#3|
Joined: Jan 2006
WOULD YOU LIKE TO DO OUR INSTUCTIONS.If you would not have said KLR650.COM I would have jumped up and down.
|06-05-2007, 06:03 AM||#7|
ZAPP - Tejas
Joined: Oct 2004
Location: Tejas Hill Country
what does the whole rig weigh... both sides combined?
"I will not let the White City fall... nor our people fail. - Aragorn
K4 WEESTROM Stealthfighter Black -SOLD - Invisible to Radar, '02 DR650SE SOLD , '97 DR650SE My Fave
|09-03-2008, 01:04 AM||#9|
Joined: May 2007
How are those combination lock barrel bolts holding up to the elements and road grit? I know this is an old thread but am interested in the long term durability of those babies...
|09-10-2008, 01:34 PM||#11|
Joined: May 2008
Location: Anchorage, AK
Very informative thread! Thanks for taking the time to go into that kind of detail.
I sometimes think I'm going overboard by posting too much info and pics - proof that there's no such thing as too many pics in too much detail!
|09-15-2008, 01:45 PM||#12|
Joined: Jun 2006
|09-15-2008, 02:02 PM||#13|
Beard Bros Racing
Joined: Mar 2007
Location: Your Mom's house
They look great!!Love the locks.
The mud gaurd on the rear,is that the tip of a front fender??
All around great look'n rig!
"Hes not called the Angry White Man for nothing,much more fitting then the,Unicorn Clouds and Happy Trees Man".... UpST8
Theres a name for people without beards,"Women".
|09-18-2008, 11:07 AM||#14|
Joined: Jun 2008
Location: Sacto, CA
Where did you get the combo locks? Are they commonly available online or in stores? I noticed from the packaging the manufacturer is British.
Bikeless for now.
|09-18-2008, 06:18 PM||#15|
Joined: Jun 2006
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