Install Tusk Pannier Racks on a 2008 & Newer Kawasaki KLR 650-Tutorial

In this video, I show you how to install Tusk Pannier Racks and Tusk Panniers on a 2018 Kawasaki KLR 650. The procedures will be the same for 2008 & newer KLR's. These racks and panniers are also available for 1987-2007 KLR's. You can also choose from medium or large size and they come in silver or black. I went with the large size and I figure if you're going to add these to your KLR then just go big and get the extra storage room. I also added Tusk Pannier Handles and Tusk Pannier Box Liners.
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Adding panniers to your KLR is a necessity if you are going to ride long distances or go beyond a simple day trip. The KLR has zero storage until you add something like this. There are other additional storage options you can add like a backpack and tank bag. I recently reviewed the Wolfman Blackhawk Adventure Tank Bag.
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[@anthonymalfino1]

Thanks Ryan. You helped me build my Harley. That’s gone. My klr is perfect for me. Thanks for the help

[@csiautodetail]

thank you for this video, is the best video I could find for this installation, not even the people who sells this rack have such a detail video.

[@jtr44]

Thank you for posting this video, made my install go smoothly.

[@hdkevin4387]

Thank you kindly for the thorough video. It was instrumental in my installation

[@WildOn2sVlog]

Always start off with coffee. Thanks for the vid

[@delav83]

Thanks for the video. Much more informative than rocky mountain video on this. I have a 2018 klr also and love it!

[@RyanUrlacher]

Thanks so much!

[@hadeadel6884]

Nice box

[@maciejnielacny4652]

IMPORTANT!
Start with left side when measuring holes. I f***ed myself and I start with right side. I wanted to have them max on the back, but because I measured from right side where exhaust is I didnt fit with left blinker -.-' Good luck. Thanks for video!

[@obamavariant9128]

You should be able to add some spacers in between the box and mount plate. Maybe that would help?

[@DG-ss1gc]

FYI. The racks when bought alone include the quick detach bracket that attaches to the pannier rack. So you can make your own side cases like I did from too opening Pelican style cases, or adapt side cases from another brand or bike to fit your KLR.

[@justanotherviewer52]

Thanks for the video. lol - my last Kawasaki was a '75 KZ-500. 3 Cylinder, 2 stroke freakin' rocket. Thankfully, I survived it and went on to a cruiser in my old age.

[@dennispluto456]

I also had the exact same bike in the 70s.your right it was a screamer and now il just cruise on my road king in my old age.

[@JosephWolf]

I see you put the left side cover on before the panier racks.
Said something about how it was designed for the right cover to come off so you can get to the air filter.
How did you put the seat bolt on the left side with the side cover there?
Thanks

[@averageguyadventures]

I love my Tusk racks but getting them tightened was a friggin' nightmare.

[@Bill-os4kf]

Question, why not use heat shrink tubing instead if electrical tape?

[@JosephWolf]

Where does one buy heat shrink tubing.
Do you slide it over one end of the wires before making the connection and then pull it back in place and melt it

[@Bill-os4kf]

@@JosephWolf can get it at auto parts store. Yes put over one end ,make connection slide over & heat to shrink

[@JosephWolf]

On it. Do the shrink wraps come different sizes?

[@robertcroll1163]

HARBOR FREIGHT has a value pack of 5 difference sizes pretty cheap

[@billw3655]

Who cares if the boxes are countered to the bike? Dual sport and adventure riders just need to pack gear. We are not trying to impress anyone. I, "we" love all bikes. Just really don't care about T- Shirt shops that might sell motorcycles.

[@DG-ss1gc]

It’s not about selling bikes or looking good. Part of a good adventure bike is ability to rack up miles overland. Boxy panniers absolutely hurt your milage potential compared to a more aerodynamic pannier design. Also a contoured pannier will do much better in tight spaces like a single track trail that may have been neglected a bit.
You also must consider that a more contoured pannier box will almost certainly be lighter. So you see there are many reasons to care if the boxes are contoured to the bike. It’s a very functional design aspect .