View source for Happy Trails SU Side Rack Install

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This guides the installation of the [[Aftermarket#Happy Trails Side Rack|Happy Trails SU side rack]] on an S or DS model.
: Fitted for a 2015 DS originally.
: Shown on 2017 DSR with stock Top Rack Below

;Reference
: [[Aftermarket#Happy Trails Side Rack|Happy Trails entry on our Aftermarket page]]
: [https://www.happy-trail.com/Instructions/HTPZ0-1-1.1.pdf Happy Trails' own install instructions, good on their own]
: [http://www.happy-trail.com/find-your-bike/zero-motorcycle/su-side-racks.html Happy Trails' Zero SU product page]

;Notes
* It is sturdy as a tank, off the bike and on; it becomes practically a part of the bike after installed.
* The tabs didn't seem to be welded all at the same angles and some of the "flat" plates were curved. (see tail plate image below)
* The spacer going through the stock rack did not go through at a perpendicular angle to the frame.
*: I had to remove the rack, then install the spacer / screw separately of the frame to get the spacer to squish into place.
*: Even then, I doubt it bottomed out. 
* The slots cut in the rack for back bar are barely enough; at first I thought it would never go on.
* The givi rack adapter instructions step 2 doesn't mention the bolts being used come from the givi pack; this caused confusion at first. Don't rely on the Step 2 image being an accurate depiction of the actual screw used.
* One of the plates my givi case had a hard time installing; the other was just tight but "snapped" into place. 
* Pictures below do not show seat bracket mounted to seat as another seat mod has been performed to make access easier.
*: See instructional pdf for tips for this step if you do not have an easy access mod installed.

;Tools
* Allen keys: 3mm, 4mm, 5mm, 6mm
* 13mm side wrench ''or'' socket with telescoping extension
* Telescoping socket extension example:
*: [[File:happy-trails-su-rack-socket-extension.jpg|thumb|none|200px|Socket extension for passenger peg bolts]]
*:# 6" extension
*:# 3" extension
*:# 2" wobble extension
*:# 2" Universal Joint extension 

;Parts
: [[File:happy-trails-su-rack-fasteners.jpg|thumb|300px|All Fasteners and Passenger-Peg Brackets]]
* ''See Happy Trails' instructions PDF above for more details''
* Left & Right rack
* Left & Right passenger-peg mounts
* Back Bar
* Bottom Tail Plate
* (4) 8M40 13mm Hex Nut Bolts
* (10) 8M Flat Washers
* (4) 8M Nylon Lock Nuts
* (4) 6M16 Allen Key Bolts
* (2) 6M25 Allen Key Bolts
* (2) 6M45 Allen Key Bolts
* (4) 6M Nylon Lock Nuts
* (12) 5M Flat Washers
* (2) 8M90 Allen Key Bolts
* (2) 5/8 OD, 0.319" ID, 1.25" Aluminum Spacer
* (2) 3/4 OD, 0.319" ID, 0.25" Aluminum Spacer
* (2) 5/8 OD, 0.319" ID, 1.0" Aluminum Spacer

;Instructions
* ''See Happy Trails' instructions PDF above''
# [[SDS Platform/Lower Plastics Removal|Remove the side plastics]] for access to the passenger peg mount bolts. 
#: (You will use a hand wrench from the battery side to access some of the passenger peg bolts)
# [[SDS Platform/Tail Extension Removal|Remove the rear fender]] via loosening the mount bolts with a 4mm Allen key wrench.
#: Tape it in place if you don't want it falling out.
# Attach the fender under-fender tab with the spacers.
#: Make sure not to pinch the two rear blinker cables when installing the back two spacers.
#: [[File:happy-trails-su-rack-1.jpg|thumb|none|200px|Underfender tab fastening]]
# Install the left passenger peg tab.
#: Use hand or box wrench to remove bottom bolts.
#: See [[SDS Platform/Passenger Footpeg Bracket/Removal|passenger footpeg bracket removal]] for a guide to these bolts.
#: [[File:happy-trails-su-rack-2.jpg|thumb|none|200px|Reaching the passenger peg mounting bolts]]
# Install the right passenger peg tab.
#: It is easier if you decompress rear shock to use socket adapters from the other side.
#: See [[SDS Platform/Passenger Footpeg Bracket/Removal|passenger footpeg bracket removal]] for a guide to these bolts.
# Attach the rack via the seat mount bolt.
#: <table><td>[[File:happy-trails-su-rack-3.jpg|thumb|none|150px|Installing the upper seat-mount bolts with spacer]]</td><td>[[File:happy-trails-su-rack-4.jpg|thumb|none|200px|Spacer forcefully installed perpendicular to frame]]</td></table>
#: '''NOTE:''' The first image shows the spacer not perpendicular to frame.
#: If the spacer cannot insert perpendicular to the frame, you have some options:
#:* Remove the rack and insert just the spacer and bolt with seat and ratchet it down so the spacer looks like the second image.
#:* Use a small rotary tool to grind the opening in the top rack bars to make space for the spacer to insert and sit properly.
# Attach the rear bar to the ends of the brackets.
#: [[File:happy-trails-su-rack-5.jpg|thumb|none|200px|Aligning the rear bar with side plates, two screws installed on right side]]
# Force left rack out while pulling rear bar in and place one screw at a time
# Install optional Givi adapter plate if purchased separately
#: [[File:Happy-trails-su-rack-givi-adapter-plate.jpeg|thumb|none|200px| Givi Plate Installed]]

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[[Category:Install]]