Need measurements for Tusk pannier rack blinker extensions - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 13 Old 02-06-2020, 09:58 PM Thread Starter
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Need measurements for Tusk pannier rack blinker extensions

So I picked up a used Tusk pannier rack, but it did not come with the blinker extensions. If you've got this rack, would you mind measuring the dimensions for me (thickness too)? Or maybe even tracing it and posting as a printable attachment? Or both? Thanks.
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post #2 of 13 Old 02-07-2020, 10:18 AM Thread Starter
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...or maybe just the length and thickness of the metal?
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post #3 of 13 Old 02-07-2020, 06:10 PM
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I can help you out but they are shaped like the letter "Z" with 2 bends in them so they are not going to be able to traced out. I'll take one off and do some measuring/pics for you. They shouldn't be all that difficult to fab up.
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post #4 of 13 Old 02-07-2020, 06:19 PM Thread Starter
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That would be much appreciated.
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post #5 of 13 Old 02-08-2020, 07:19 PM
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Can't find my old thickness gauge but if I do I'll post up the measurements. Hope this gives you an idea of how to make a pair. Kinda surprised that rockymountain atv doesn't sell these as spares. Might want to contact them and ask if they would.






Edit: 3.175mm or 0.125 inches thick

Last edited by JTCrow; 02-08-2020 at 09:02 PM.
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post #6 of 13 Old 02-08-2020, 11:26 PM Thread Starter
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I probably should have posted these pics first before you went to that trouble. I think you might have a first gen KLR. Mine's a second gen, 2008 and, as these pics show, the blinker and the mounting position have two holes each. The stock pic of the rack shows the extensions that I need to create in the lower right corner. I really appreciate you going to all that trouble for me. Hopefully someone has a second gen setup and can do the same. What's puzzling is that the stock pic of the extensions do not look like they have a z bend to them. I don't know why there would be that big of a difference in the extensions between first and second gen.
Attached Images
File Type: jpg KLR Blinker.jpg (82.2 KB, 12 views)
File Type: jpg pannier rack.jpg (15.0 KB, 10 views)

Last edited by Schoen; 02-09-2020 at 04:36 PM.
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post #7 of 13 Old 02-09-2020, 10:31 AM Thread Starter
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...and rockymountain atv said they don't sell the extensions. However, they did sell me the left blinker extension WIRE (which also did not come with the used rack).

Last edited by Schoen; 02-09-2020 at 10:34 AM.
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post #8 of 13 Old 02-09-2020, 11:30 AM
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I should have realized the gen 1 +2 difference, doh! Anyways, happy to do it, sorry it didn't help. Hopefully someone comes along that has a gen 2 rack and can do some measurement for you. Good luck.
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post #9 of 13 Old 02-09-2020, 04:39 PM
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Quote:
Originally Posted by Schoen View Post
I probably should have posted these pics first before you went to that trouble. I think you might have a first gen KLR. Mine's a second gen, 2008 and, as these pics show, the blinker and the mounting position have two holes each. The stock pic of the rack shows the extensions that I need to create in the lower right corner. I really appreciate you going to all that trouble for me. Hopefully someone has a second gen setup (if that, in fact is the difference) and can do the same. What's puzzling is that the stock pic of the extensions do not look like they have a z bend to them. I don't know why there would be that big of a difference in the extensions between first and second gen.
We many times forget to look at the top header to see which sub-forum that we are currently reading.

If you go to USER CP in upper RH corner and create a signature line that includes your bike, it can be helpful in the future.

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post #10 of 13 Old 02-11-2020, 02:27 PM
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Hi,
I'm new to the forum, but hopefully I can help. I have an '09 KLR 650 with Tusk Pannier Rack. I took pictures to go along with the info below, but I do not see a way to post them (there is a reason I like a simple motorcycle). If someone can educate me, I will try to post them.

The turn signal extension piece is just flat steel stock .182" (3/16" will work) thick X 1"x 4 11/16". There are no bends, but there are four 5/16" holes (larger than needed), and a radius recess to clear where one of the rack tubes is welded to a mounting plate.

The Tusk design eliminates the rubber vibration dampeners in the KLR frame that the turn signals normally mount to, and replace them with shaped pieces of steel .234"thick (1/4" will work). These mount behind the frame (wheel side) where the rubber pieces originally were. They made these with nuts welded on as it is kind of difficult to reach inside the frame. If I were making them, I would just tap them. They are a bit of an odd shape, but you can just use the rubber insert as a pattern for the shape & to align the holes. You can use that same rubber insert to align the holes on the flat extension piece by placing the rubber flush with the ends of the plate. I do think the shaped pieces inside the frame are needed as the turn signal mounting method (steel frame cutout & rubber dampener) was never intended to support all that much weight.

If you can get access to the original Tusk installation instructions, it might save you some frustration. The turn signal wires are not long enough to reach to the new signal locations, but if you re-rout the wires under the seat, you only need to extend the one side.
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