I have been temporarily affixing five different sizes of Pelicans on the top rack for about two months and have finally decided that the 1520 is the way to go. More storage, more crash protection in a slow speed dump and the ability to mount other case systems all contributed to this decision. BTW I tried everything from the 1200 series up to the 1550's.
Today after lunch, I realized that the weather was great and I have been putting off my Pelican install for 3 weeks. I know, I know...what kind of KLR owner am I if I procrastinate on simple stuff like this.
Here is how it went. Total time 45 minutes from start to finish, including mods to case, patterning, etc... Unfortunately no beer was harmed during this modification.
(1) Pelican 1520 Case.........................$40.00 (3 years ago)
(4) M6 X 30 socket caps screws...........$1.20 total @ Ace Hardware
(4) 1/4 inch fender washers.................$1.40 total @ Ace Hardware
(4) 1/4 inch rubber grommets...............$1.20 total @ Ace Hardware
5mm Hex Tool to install new M6 bolts to hold Pelican case onto rack
1/4 inch drive to remove screws on rear rack
8mm socket (1/4 " drive) to fit screws on rear rack
Nice sharp mitre or hacksaw for case mod
Assemble all the parts.
Remove the rear rack assembly.
Use the rear rack as a template and position on the bottom of the case in the position that you want the case to be in when mounted, drill the case, and then cut the interference points out of the way with a mitre saw to clear the metal handholds on the rear.
Install the rear rack assembly with the forward two outside M6 factory screws and the two longer bolts in the middle position aft of the tool kit.
Drop rubber grommets into the four remaining countersink positions on the factory rack and install the case with the new M6 X 30 bolts and fender washers. Tighten to rack.
Check for interference points, if none step back and admire your work. Proceed to iced cold beverage stage of maintenance regime.....LOL
Hope someone finds this helpful.
P.S. removed the rear reflector and raised the tag about an hour later....man, I'm on a hot streak LOL