ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 06-03-2007, 08:22 PM   #1
klm4755 OP
Studly Adventurer
 
Joined: Jun 2006
Oddometer: 574
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
5. Waterproof
6. More carry than dirt bagz
7. Small drag hit
8 removable from bike
the companies web site is here:
http://happy-trail.com/ProductInfo.a...=PANKIT-OWYHEE

boxes as delivered.

latch mechanism. Accepts a pad lock

lift the latch

twist

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

more 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

install instructions

reference views

attach brackets
measure centerline

mark centerline

gage of bracket

mark first hole

drill

deburr

like so. Do inside of pannier also

finish 3x holes totals to attach bracket

inside view

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

like so

attach opposite side

meets requirements

enhances look of bike, but that of course is a truly secondary consideration! Hehehe

just the right size

when opened

new bike width = 34.5 inches

decals that were delivered with boxes

like this one

sweet

looks nice

only used "trail" from the happy-trails.com

trimmed and tossed the other text
Review:
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
Keithm

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

outside view

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. Won’t fit in drill press

need self locking 3/16 nut

ready for install

drill/de-burr

install fasteners

check latch has free play

one down, 3x to go!

on the bike

fwd view

closeup view

inside view
Review:
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!
Keithm
klm4755 is offline   Reply With Quote
Old 06-03-2007, 08:27 PM   #2
klm4755 OP
Studly Adventurer
 
Joined: Jun 2006
Oddometer: 574
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
Enjoy!
Keithm

klm4755 screwed with this post 06-03-2007 at 08:33 PM
klm4755 is offline   Reply With Quote
Old 06-03-2007, 08:49 PM   #3
capt ed
Capt Ed
 
capt ed's Avatar
 
Joined: Jan 2006
Location: Boise,Id
Oddometer: 527
great pictures

WOULD YOU LIKE TO DO OUR INSTUCTIONS.If you would not have said KLR650.COM I would have jumped up and down.
capt ed is offline   Reply With Quote
Old 06-04-2007, 06:32 PM   #4
klm4755 OP
Studly Adventurer
 
Joined: Jun 2006
Oddometer: 574
Happy trails makes a great product.
Keith
klm4755 is offline   Reply With Quote
Old 06-04-2007, 08:41 PM   #5
Tucos
Gnarly Adventurer
 
Tucos's Avatar
 
Joined: Mar 2007
Location: Center, Colorado
Oddometer: 307
Nice write up. Cool idea with the combo bolt. I didnt know such a contraption existed.
Tucos is offline   Reply With Quote
Old 06-04-2007, 10:31 PM   #6
haggeo
Studly Adventurer
 
haggeo's Avatar
 
Joined: Aug 2005
Location: oakland, ca
Oddometer: 849
is that a corbin dished seat you switched to? has a different sort of dip to it.
haggeo is offline   Reply With Quote
Old 06-05-2007, 05:03 AM   #7
Zapp22
ZAPP - Tejas
 
Zapp22's Avatar
 
Joined: Oct 2004
Location: Tejas Hill Country
Oddometer: 13,600
what does the whole rig weigh... both sides combined?
__________________
Zapp
"I will not let the White City fall... nor our people fail.” - Aragorn
K4 WEESTROM Stealthfighter Black -SOLD - Invisible to Radar, '02 DR650SE SOLD ,'Ole 97' DR650SE My Fave K5 WEESTROM ADVbomber
Zapp22 is offline   Reply With Quote
Old 06-05-2007, 06:35 AM   #8
klm4755 OP
Studly Adventurer
 
Joined: Jun 2006
Oddometer: 574
That seat is "rich's" custom Motorcycle seat from Seattle. $400
Keith
klm4755 is offline   Reply With Quote
Old 09-03-2008, 12:04 AM   #9
Cedartree
Adventurer
 
Joined: May 2007
Oddometer: 13
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...
Cedartree is offline   Reply With Quote
Old 09-03-2008, 05:41 AM   #10
liquidmonkey
Adventurer
 
Joined: Aug 2008
Oddometer: 16
Thumb

i'm a bit new here but WOW!! what a great post!!
well done and thank you!!
liquidmonkey is offline   Reply With Quote
Old 09-10-2008, 12:34 PM   #11
ak_flyfisher_ak
Adventurer
 
ak_flyfisher_ak's Avatar
 
Joined: May 2008
Location: Anchorage, AK
Oddometer: 61
Laugh Agree

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!
ak_flyfisher_ak is offline   Reply With Quote
Old 09-15-2008, 12:45 PM   #12
klm4755 OP
Studly Adventurer
 
Joined: Jun 2006
Oddometer: 574
Quote:
Originally Posted by Cedartree
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...
The locks are working graet no signs of degredation or issues with the mechanism. Real nice to have a hassle free, keyless, one hand operation, robust locking system. Highly recommended!
Keithm
klm4755 is offline   Reply With Quote
Old 09-15-2008, 01:02 PM   #13
AWM
Beard Bros Racing
 
AWM's Avatar
 
Joined: Mar 2007
Location: Your Mom's house
Oddometer: 11,321
Great job!!!

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".
AWM is offline   Reply With Quote
Old 09-18-2008, 10:07 AM   #14
Twinsteel
Gnarly Adventurer
 
Twinsteel's Avatar
 
Joined: Jun 2008
Location: Sacto, CA
Oddometer: 464
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.
Twinsteel is offline   Reply With Quote
Old 09-18-2008, 05:18 PM   #15
klm4755 OP
Studly Adventurer
 
Joined: Jun 2006
Oddometer: 574
Quote:
Originally Posted by Twinsteel
Where did you get the combo locks? Are they commonly available online or in stores? I noticed from the packaging the manufacturer is British.
I looked, but have no record of the supplying vendor. I did obtain them thru the internet. I little web searching should work, given the keywords off the package.
Keithm
klm4755 is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 03:57 AM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014