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[Aikirob]

hello,

I want to fit some hard weatherproof saddlebags to my 2016 dsr, zero wants over $1000 AUD for top box and side racking, which is a bit of a hell no from me, who would pay that exorbitant amount of money just for racking without the boxes...

so I'm looking for a cheaper alternative, would prefer steel racking, I am thinking of using aluminum piping and an arc welder which will set me back about $200 (or more), but I've never welded anything before so there might be a learning curve there...

Anyone got any links to others who have installed their own or third party parts that are much cheaper?

[Shadow]

Happy Trails SU racks are sturdy. @BrianTRice owns a set that I've seen in person and would recommend for your consideration.

The OEM toprack bracket I don't think anyone has done a better 3rd party version of it. I have one installed and it's good enough but not exceptionally sturdy for unusual top loads.

These options are expensive but if they're right for you then the cost will soon be easy to forget.

[BrianTRice@gmail.com]

^ Well, what he said. The Happy Trails rack is sturdier and cheaper than Zero's.

If you buy the top rack alone, you can just put any case on it you can acquire locally; it doesn't include the Givi adapter. To go really cheap, just drill holes in a case's bottom and fasten it really well to the metal plate.

The Happy Trails probably doesn't need the OEM top rack being installed first, unlike the OEM side rack.

General community wiki writeup of options:
http://zeromanual.com/index.php/Zero_Aftermarket#Luggage

[Erasmo]

Shipping to Australia might be a bit expensive though... Perhaps a local welder can put something together?

[Aikirob]

Happy Trails SU racks are sturdy. @BrianTRice owns a set that I've seen in person and would recommend for your consideration.

The OEM toprack bracket I don't think anyone has done a better 3rd party version of it. I have one installed and it's good enough but not exceptionally sturdy for unusual top loads.

These options are expensive but if they're right for you then the cost will soon be easy to forget.

will cost about the same in Australia though due to bad currency and large shipping

[Aikirob]

Instead of wasting my time and money trying to get zero's cooperation in installing some saddlebags and racking on my 2016 zero dsr, I just went out and bought an arc welder, 4 steel tubes, an angle grinder, two small aluminum lock tool boxes, some safety gear and made up a work bench for about $320, I'm now going to weld together my own racking for my bike which should be much stronger since its steel.

could somebody please post up how zero connect up their side racking with some pictures so I can copy where to mount from?

[NEW2elec]

As far as I know they just connect with longer alan bolts where the seat is attached to the frame.
My opinion would be to also brace against the passenger peg bracket if your going for strength.
But remember your dealing with an aluminum frame and motor weight limits so try not to go too overboard with the packing.
Still a good do it yourself attitude is to be commented, good luck and post what you come up with.

[ChainGun]

After 10 years with a gigantic Suzuki DL-650 and top box, I couldn't bring myself to install a top box on my Zero S, it looks just too damn ugly. My alternative is a Ogio Mach 5 backpack. I know, an 22 litre backpack is no comparison to a 40 litre top box but for the last year I learned to live without a top box and a very sexy looking (IMHO) backpack as a replacement.

[BrianTRice@gmail.com]

Instead of wasting my time and money trying to get zero's cooperation in installing some saddlebags and racking on my 2016 zero dsr, I just went out and bought an arc welder, 4 steel tubes, an angle grinder, two small aluminum lock tool boxes, some safety gear and made up a work bench for about $320, I'm now going to weld together my own racking for my bike which should be much stronger since its steel.

I know you're frustrated, but claiming that Zero is non-cooperative is not fair. Shipping to your region is not cheap for anybody.

If you can weld, you should be able to make a decent mount.

could somebody please post up how zero connect up their side racking with some pictures so I can copy where to mount from?

If you actually click through to the Happy Trails SU rack product page, the instructions are posted in a PDF with photos. They're quite good and illustrate both how you'd attach it and what fasteners they used.

Honestly I'd bet if you emailed them, they'd give you some guidance. If I've learned anything in the past year, it's that vendors are often happy to help inform people with needs that don't quite match the product lineup.

[Aikirob]

I've gotten started, welded up some squares out of steel tubes, now comes the hard part of figuring out how to attach the first support brackets, will get pictures once I've got it mounted to the bike

[madcow]

http://shop.sw-motech.com/nocache/en/by+motorbike+or+scooter/Zero/DSR/index,w149068807617053.htm

This is a German accessories manufacturer who just released a few aftermarket parts for the Zero DSR (should also fit DS/S/SR in most cases). Price might seem great but afaik they'd charge you 106€ for shipping (roughly USD115 ) to Australia :/

[gyrocyclist]

I've gotten started, welded up some squares out of steel tubes, now comes the hard part of figuring out how to attach the first support brackets, will get pictures once I've got it mounted to the bike

Can't wait to see the pics!

I bought the ZERO 22-LITER SIDE CASES BY GIVI AND RACK KIT, and also the top box
 http://www.zeromotorcycles.com/shop/index.php?main_page=product_info&cPath=15_7&products_id=232
http://www.zeromotorcycles.com/shop/index.php?main_page=product_info&cPath=15_7&products_id=161

The top box is only rated to carry 3kg. Am guessing and hoping that is a "lawyer designed" limit.
The side bags are rated at 5kg, but it's unclear to me if that's per bag, or total.

I quickly realized I didn't have the tools or patience to install the rack myself.
I took it to a local dealer who charged an hour of time. And I'm pretty sure it
took them a bit longer than an hour. It was worth it to me. Especially after the
fourth mechanic I spoke with mentioned how difficult/annoying/rube goldberish
it was to install.

I'd really like to know how much weight I can safely carry in each side bag and the top box.

I'd like to have a rack that I know can safely handle 33 pounds (bicycle + riding gear)

[BrianTRice@gmail.com]

http://shop.sw-motech.com/nocache/en/by+motorbike+or+scooter/Zero/DSR/index,w149068807617053.htm

This is a German accessories manufacturer who just released a few aftermarket parts for the Zero DSR (should also fit DS/S/SR in most cases). Price might seem great but afaik they'd charge you 106€ for shipping (roughly USD115 ) to Australia :/

Great find! SW-Motech makes the Aero and TraX cases I've used on my V-Storm and temporarily on my DS.  It looks like the side racks are removable, which is handy.

The Aero cases are light but rigid and obviously pretty aerodynamic for their size (33L I seem to recall). Givi V35s are better but require a specific rack not yet supported.

I'll check further later to add to the wiki. Maybe they're available soon through a retailer like Twisted Throttle with better shipping prices.

[Doug S]

I'd really like to know how much weight I can safely carry in each side bag and the top box.

I don't have the saddlebags, but I do have the Zero rack, on which I've fastened the largest Givi box I can find.

I've thrown 30-lb boxes of kitty litter in there and it's fine. The handling is affected a bit, but that's always going to be true whenever you add weight up high. I'm sure you're right, the ridiculous weight limit is liability-based. If you get in an accident and your bowling ball causes the trunk to break off and smack you in the back, they can just say you violated the weight limit.

I can't for the life of me figure out what somebody could fill a 43 liter box with that would weigh no more than 3 kg.

[BrianTRice@gmail.com]

I'd really like to know how much weight I can safely carry in each side bag and the top box.

I'd like to have a rack that I know can safely handle 33 pounds (bicycle + riding gear)

The Happy Trails SU rack for the Zero will handle it better than Zero's rack but both are probably acceptable.

Make sure your rack is very securely mounted before using it regularly like that; I had to make sure that the the top rack wouldn't wave around over bumpy highways (880) because the tab didn't sit firmly on the tail.