Honda XR650L Pannier Racks

Installation Guideline for the Toys2Go Honda XR650L Pannier Racks
17 April 2016
Part
Description
Qty
1
Pannier Frame, Left Side
1
2
Pannier Frame, Right Side
1
3
Rear Brace
1
4
Bolt, Hex, M6x30
2
5
Bolt, Hex, M6x75
2
6
Bolt, Allen Cap, M8x20
2
7
Bolt, Hex, M8x25
4
8
Washer, Flat, M6, Standard
4
9
Washer, Flat, M6, Large
4
10
Washer, Spring, M6
2
11
Washer, Flat, M8
14
12
Nut, Nyloc, M6
2
13
Nut, Nyloc, M8
2
Notes:
1. The installation of the pannier racks are done by executing the following steps sequentially.
2. Do not tighten fasteners until all have been installed and are in place.
1
2
3
4
7
10
11
8
6
5
11
13
9
8
12
Step 1
Remove the bolts that attach the passenger foot
pegs on both sides of the motorbike.
Step 2
Remove the existing mounting bolt for the rear
indicator on both sides of the motorcycle.
Step 3
Using the M6x75 bolt (5), one large M6 flat washer (9),
two standard M6 flat washers (8) and an M6 nyloc nut
(12), attach the left pannier top attachment point to the
indicator mounting point. The large washer is between
the bolt head and the rack. The small washer is used on
the inside of the frame with the nut and in between the
rack and indicator mount.
Repeat for the right hand side of the motorcycle.
NB: Do not tighten the bolt and nut.
Step 4
Using the M8x25 hex bolt (7) and two M8 washers
(11) for each of the four attachment points, mount
the bottom of the pannier rack on both sides of the
motorcycle to the passenger foot peg mount points.
The passenger footpegs may be retained if required.
The additional washer fits between the rack and the
foot peg.
NB: Do not tighten the bolt and nut.
Step 5
Remove the existing bolts from underneath the rear
fender that holds the taillight unit in place.
NB: Remove very carefully so as not to misplace
the internal retainer plate. If this happens, the
number plate will have to be removed in order to
reposition the plate again. Glue (Genkem or
equivalent) can be used to secure in place.
Step 6
Position the rear brace into position and using an M8x20
cap screw (6), three M8 flat washers (11) and an M8
nyloc nut (13) on each side, attach the brace to the left
and right pannier brackets respectively.
NB: Do not tighten the bolt and nut.
Step 7
Using the two M6x30 hex bolts (4) and two M6 flat washers
(8) and two M6 spring washers (10), attach the top of the
rear brace to the underside of the fender.
NB: Attach the bolts very carefully so as not to misplace
the internal retainer plate. If this happens, the number
plate will have to be removed in order to reposition the
plate again.
Do not tighten the bolts yet
Step 8
With all parts and fasteners in place, tighten all nuts and bolts
accordingly.