Happy Trails SU Side Rack Install

From Unofficial Zero Manual
Jump to: navigation, search

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
Happy Trails entry on our Aftermarket page
Happy Trails' own install instructions, good on their own
Happy Trails' Zero SU product page
  • 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.
  • Allen keys: 3mm, 4mm, 5mm, 6mm
  • 13mm side wrench or socket with telescoping extension
  • Telescoping socket extension example:
    Socket extension for passenger peg bolts
    1. 6" extension
    2. 3" extension
    3. 2" wobble extension
    4. 2" Universal Joint extension
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
  • 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 with a 4mm Allen key wrench.
    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 pinch 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.
    See passenger footpeg bracket removal for a guide to these 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 adapters from the other side.
    See passenger footpeg bracket removal for a guide to these bolts.
  6. Attach the rack via the seat mount bolt.
    Installing the upper seat-mount bolts with spacer
    Spacer forcefully installed perpendicular to frame
    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.
  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