What is up with all the TOP BOXES?

Discussion in 'The Perfect Line and Other Riding Myths' started by DAKEZ, Jul 16, 2008.

  1. Wy'east

    Wy'east Dust in the wind...

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    Like I said,"just an observation". Off-topic for a second, I don't doubt their trips are fun, but I wonder how sterile they are. It seems like they have their logistics down in terms of shipping your bike from A to B. Anyway...

    I personally have never used a top-box, so I can't give any :thumbup for them, but after read the posts here I can surely see how they're useful when commuting around town.

    I'm more for the stuff-sack/dry-bag arrangement myself.
  2. mikesova

    mikesova Michigander

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    I love that bike. drool.
  3. Jnich77

    Jnich77 Been here awhile

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    Awww thank you :-)
  4. ADW

    ADW 'tard bike restos

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    (Shoulda quoted the original post more: this pertains to installing a Pelican 1500 case on a '08 and '06 KLR650)
    First I took the luggage rack off the bike and figured out where I wanted my retaining points. I then drilled holes for these pins that have holes through them for putting through a cotterpin or similar. I don't have a photo of the bottom of the rack, but each of the pins goes through a steel portion of the rack for strength.
    [​IMG]

    Then I inverted the luggage rack and put it on the bottom of the Pelican to mark the hole positions. Drilled the holes and made 'em just a teensy bit oversized to the pins. Don't want too much slop but don't want to have to position the case with 1/2mm precision to get it to slip over the pins either.

    Here's what we end up with (I made a t-bar out of strap metal pop-riveted together to spread the load. Obviously you've gotta plan your holes on the rack and case to fit the spacing of the holes on the strap metal). You could of course use fender washers instead of the strap metal.
    [​IMG]

    Then you mark the too-tall pins for where you need to cut 'em off. Remove them and do so, and file or grind the cut ends to a bit of a chamfer. Here's the final outcome.
    [​IMG]

    With this setup the case is very firmly attached, is easily removable, yet is secured to the bike once you lock the Pelican case since nobody can get inside to remove the hairpins. I carry all my tools and stuff that I want on the bike every day in the case, and keep my "removables" in sidebags or elsewhere. So you can either remove it when you go into a hotel room at night or can leave it on the bike locked up.

    The other beauty of this setup is I have 2 KLRs. One is my 2 wheel ADV bike, the other is a 06 attached to a Sputnik sidecar for my wife and I. I have the same setup on the '06 sidecar rig so I can move the tailcase to whichever bike I'm going to use. Makes it easy to be sure I have all the stuff I may need for repairs on either bike. Yes, you do have to empty the box to get down to the pins to disconnect it, but it's a minor hassle. I'm good at it now, I know how everything fits just so so I can unload, transfer the box to the other bike, and shut the lid done in 3 minutes.

    PS: I do have a piece of thin rubber over the bottom of the case/strapping/pins to protect the contents from the tiny bit of protruding pins. I just used some of that perforated rubber like you use to line toolbox drawers. Works well.

    Here it is on the '06 w/sidecar.
    [​IMG]

    Here's the luggage rack on the '08 with the case NOT mounted. I choose to leave the pins mounted to the rack even when the case isn't on there. Just easier that way for me. I retain the pins by using smaller hairpin clips to keep them "sitting up" above the surface so they are ready to accept the case.
    [​IMG]

    However, I've found when I throw my leg over the empty rack, the pins stick up enough to catch my pantleg once in a while. So I just cut some rubber spacers to put over the pins to help "shed" the fabric and not catch it so bad. Works well. I just transfer the rubber spacers and small hairpins to whichever KLR doesn't have the tailbox on it.
    [​IMG]

    Inexpensive, easy to make, and very sturdy. Have run this setup multiple thousands of miles and it holds the case very securely and is showing no signs at all of wear. Hope this helps!
  5. TacocaT

    TacocaT Been here awhile

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    the other Redmond
    My sweet Igloo topbox at the office yesterday.
    [​IMG]
  6. Jettn Jim

    Jettn Jim This is Liv'n!!!

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    Nice job... only thing I'll add is that you don't need the strapping. Just use a fender washer on each pin then clip em and your good to go. :freaky
  7. ADW

    ADW 'tard bike restos

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    Yep, understood. But I had the strapping around so decided to use it (in true KLR style)!
  8. speedmonkey7

    speedmonkey7 Been here awhile

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    Hey nice....here's mine! [​IMG]
    The only thing I don't Luke is when it hits me in the ass on steep descents lol. :eek:

    Sent from my SAMSUNG-SGH-I997
  9. ty.zardoz

    ty.zardoz Adventurer

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    Nova Scotia
    Any suggestions on how to add a box or even a decent rack to my bike?

    [​IMG]


    tyz
  10. mikesova

    mikesova Michigander

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    Normally you would attach a box to a rack, which is attached to a subframe, which yours seems to be missing. What did you or the previous owner do to a perfectly good TW200?
  11. ty.zardoz

    ty.zardoz Adventurer

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    The po/builder used the 2008 TW as a commuter bike and blew up the engine. So rather than re-build or replace with stock he decided to adapt the bike to accept a 2003 yz250f engine. Personally I think he did an exceptional job! Everyone has their own "vision" and we don't all have to see things the same as the other guy. The engine swap has doubled the hp in this cool little bike, I'm going to extend the swinger for next summer to help settle down the front end (also for looks... yeah kinda shallow I know.. but I like the look of an extended swinger) the front end gets kinda "twitchy" under hard acceleration. At speed when I'm off the throttle she rides beautifully and very stable.. so I'm fairly certain the "twitch" is a direct result of the engine being in a frame that is roughly 6 inchs shorter in wheelbase.

    tyz
  12. Jettn Jim

    Jettn Jim This is Liv'n!!!

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    AWESOME creation... I think your bike requires a Backpack approach!.:lol3
  13. mikesova

    mikesova Michigander

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    Did the subframe need to be removed to fit the engine? I mean, I don't want to sound like I hate it or anything. I just don't like mods that take away from utility for the sake of cosmetics. I wonder if you could re-attach a subframe ?

    Other than that, I second the thought on the backpack idea. ;)
  14. Jettn Jim

    Jettn Jim This is Liv'n!!!

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    I see your located in NS.... I'm in Cape Breton right now. A few clicks South of Sydney off Lac Bras D'or
  15. ty.zardoz

    ty.zardoz Adventurer

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    Yeah.. I was thinking the same.. but really would like to be able to carry more than a backpack can tote. I'm seriously considering one of these
    [​IMG]


    Plus I really DON'T like riding with a backpack.

    tyz
  16. ty.zardoz

    ty.zardoz Adventurer

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    No the sub frame was removed for aesthetics. The bike's utility has been down graded anyhow seeing as it now has a yz250f engine.. with it's accelerated valve wear etc... Personally I would rather he had transplanted a less maintenance intensive engine.. but what are ya gonna do :)

    I might consider adding some support framework on the swinger to carry a couple of ammo cans.. unsure tho as they are somewhat less "elegant" than I'd really like to see on my little bike.. thoughts on what might serve better (look more "stylish")?

    tyz
  17. ty.zardoz

    ty.zardoz Adventurer

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    Great area for a ride!!! I'll be doing a trip out that way next summer :)

    tyz
  18. DC2wheels

    DC2wheels Castle Anthrax troll

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    Come on....find some fugly ugly topbox, three or four holes in that rear fender, some bolts and fender washers (they are even named correctly) and you will be honored with a Holee Chit posting here.
  19. dmottv

    dmottv Take the Long Way Home

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    The action packer somehow looks just right on the KLR:

    [​IMG]


    works well too, these pics from a recent ride through the Gaspe:

    [​IMG]


    [​IMG]
  20. nashopolis

    nashopolis Been here awhile

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    Nashville, Tenn
    General question
    what's your the trick to not kick your top case when mounting and dismounting the bike?

    Stand on the pegs - then swing a leg over? Easy enough getting on the bike but always feels weird on the dismount to me.

    Thinking about adding a topbox to my little dr250 but imagine myself tripping over it daily.