Difference between revisions of "Happy Trails SU Side Rack Install"

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# Force left rack out while pulling rear bar in and place one screw at a time
 
# Force left rack out while pulling rear bar in and place one screw at a time
 
# Install optional Givi adapter plate if purchased separately
 
# Install optional Givi adapter plate if purchased separately
#: [[Happy-trails-su-rack-givi-adapter-plate.jpeg|thumb|none|200px| Givi Plate Installed]]
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#: [[File:Happy-trails-su-rack-givi-adapter-plate.jpeg|thumb|none|200px| Givi Plate Installed]]
  
 
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[[Category:Procedure]]
 
[[Category:Procedure]]

Revision as of 21:52, 2 July 2018

This guides the installation of the 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
Happy Trails entry on our Aftermarket page
Happy Trails' own install instructions, good on their own
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.
Parts
All Fasteners and Passenger-Peg Brackets
Tools
  • Socket extension for passenger peg bolts
  • Pictured:
  1. 6" extension
  2. 3" extension
  3. 2" wobble extension
  4. 2" Universal Joint extension
Parts
  • See Happy Trails' instructions PDF above for more details
  1. Left / Right rack
  2. Left / Right passenger-peg mounts
  3. Back Bar
  4. Bottom Tail Plate
  5. 4 x 8M40 13mm Hex Nut Bolts
  6. 10 x 8M Flat Washers
  7. 4 x 8M Nylon Lock Nuts
  8. 4 x 6M16 Allen Key Bolts
  9. 2 x 6M25 Allen Key Bolts
  10. 2 x 6M45 Allen Key Bolts
  11. 4 x 6M Nylon Lock Nuts
  12. 12 x 5M Flat Washers
  13. 2 x 8M90 Allen Key Bolts
  14. 2 x 5/8 OD, 0.319" ID, 1.25" Aluminum Spacer
  15. 2 x 3/4 OD, 0.319" ID, 0.25" Aluminum Spacer
  16. 2 x 5/8 OD, 0.319" ID, 1.0" Aluminum Spacer
Instructions
  • See Happy Trails' instructions PDF above
  1. 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)
  2. Remove the rear fender via loosening the mount bolts.
    (tape it in place if you don't want it falling out)
  3. Attach the fender under-fender tab with the spacers.
    Make sure not to squish the two rear blinker cables when installing the back two spacers)
    Underfender tab fastening
  4. Install the left passenger peg tab. (use hand or box wrench to remove bottom bolts)
    Reaching the passenger peg mounting bolts
  5. Install the right passenger peg tab. (It is easier if you decompress rear shock to use socket adatpers from the other side)
  6. Attach the rack via the seat mount bolt.
    Installing the upper seat-mount bolts with spacer
    Spacer forcefully installed perpendicular to frame
    (note first image shows spacer not perpendicular to frame. If this happens remove rack and insert just the spacer and bolt with seat and ratchet it down so the spacer looks like the second image [ see 4th note above ])
  7. Attach the rear bar to the ends of the brackets.
    Aligning the rear bar with side plates, two screws installed on right side
  8. Force left rack out while pulling rear bar in and place one screw at a time
  9. Install optional Givi adapter plate if purchased separately
    Givi Plate Installed