ElectricMotorcycleForum.com
Tech => Parts, Mods And Hacks => Topic started by: Ethestral on January 15, 2019, 06:29:36 AM
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I have just about wrapped up mounting boxes to the 2016 DSR, this has been in the works since I bought the bike new! First plan was to weld up a custom frame. Then life happened.
You can find the SW-Motech rack listed here twisted throttle:
https://www.twistedthrottle.com/sw-motech-quick-lock-evo-side-carriers-to-fit-many-side-case-types-for-zero-dsr-15-17
(https://farm5.staticflickr.com/4849/46020815584_3ed7449687_z.jpg) (https://flic.kr/p/2d7GH8E)20181101_114733 (https://flic.kr/p/2d7GH8E) by Ethestral (https://www.flickr.com/photos/ichamber/), on Flickr
I had to drill two new holes to get the plate adapter to mount properly.
(https://farm8.staticflickr.com/7820/45830013175_3c2e674d9e.jpg) (https://flic.kr/p/2cPQNdX)20181101_105213 (https://flic.kr/p/2cPQNdX) by Ethestral (https://www.flickr.com/photos/ichamber/), on Flickr
(https://farm8.staticflickr.com/7838/45830013325_0bb064cd4e.jpg) (https://flic.kr/p/2cPQNgx)20181101_112403 (https://flic.kr/p/2cPQNgx) by Ethestral (https://www.flickr.com/photos/ichamber/), on Flickr
I already had the Touratech boxes (bought for the custom build) so I didn't buy the SW Motech boxes. It did mean I had to adjust the mounting hardware to get them to mount properly. I will still need to add a 1/8" spacer to keep them from rattling as the SW Motech rack is just that much smaller than the Touratech rack system.
(https://farm5.staticflickr.com/4895/32870218958_4bc1b093bd_z.jpg) (https://flic.kr/p/S5CsV5)20190113_125607 (https://flic.kr/p/S5CsV5) by Ethestral (https://www.flickr.com/photos/ichamber/), on Flickr
Here you see the turn signals relocated, I scratched my head about where to put them as the rack install instructions include zip tying the extended leads to the narrow plastic piece that holds the plate from the factory. Using 14 ga wire (4 strands), adding a cable keyway (one already present for the plate light) and enlarging the weep hole at the base of the license stalk assembly I was able to extend the wires inside factory body work for the relocated turn signals.
(https://farm5.staticflickr.com/4904/31803951867_39e9552024_z.jpg) (https://flic.kr/p/QspyRH)20190113_130318 (https://flic.kr/p/QspyRH) by Ethestral (https://www.flickr.com/photos/ichamber/), on Flickr
(https://farm5.staticflickr.com/4901/31803951857_dd35719d21_z.jpg) (https://flic.kr/p/QspyRx)20190113_130235 (https://flic.kr/p/QspyRx) by Ethestral (https://www.flickr.com/photos/ichamber/), on Flickr
These are the large boxes, big enough to fit a large full face helmet. I have no idea what it will do to my efficiency yet but I can say I am happy to have them on the bike for sure. Aside from drilling some holes there are few tools needed to install this system. Additionally it uses the same strong points I planned to use. I had planned to use the passenger peg mounting bolt locations but the clamp style seems to work alright.
No these boxes will not survive a Dakar rally, but neither would I. Let me know if there are questions.
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Nice! Some advice:
- Keep your highway speed down to avoid range loss *and* excessive motor or battery heating. This has happened to another Zero DSR rider with adventure cases.
- For others considering the SW-Motech rack, they make good racks, but their Zero rack doesn't work with the Zero top rack (which is the only top rack for Zero bikes!). I tend to recommend the Happy Trails rack which is also much sturdier.
I wish we had a set of side cases we could install on Zero's that wouldn't impact range. SW-Motech Aero cases are pretty good but are only 25L (31L for the older models I had for a while). A teardrop-shaped narrow and tall set of side cases would be ideal, especially if they could get close to 40L of capacity per side.
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Nice! I tend to recommend the Happy Trails rack which is also much sturdier.
Do you know if Happy Trails racks will work on an SR with the Zero top-rack installed? (I wrote the company and they replied, "don't know")
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Nice! I tend to recommend the Happy Trails rack which is also much sturdier.
Do you know if Happy Trails racks will work on an SR with the Zero top-rack installed? (I wrote the company and they replied, "don't know")
Yes, and Togo has done this.
The side rack is a very tight fit around the foot peg brackets and rear shock cylinder, but does work with the top rack.