Fitting Touratech Panniers for Transalp 650 - part 2

The fitting instructions that come with Touratech panniers are in german, so here I've attempted to describe how I fitted my panniers in english.

Disclaimer, this is how I fitted the panniers and frame, I didn't consult the german instructions and take no responsibility for the contents or accuracy of this guide.

To save some cash I purchased the pannier set without the mounting pucks fitted, outlined below is how I fitted these in the appropriate place on the panniers.

Section 2 - Fixing the pucks to the panniers

 

1. I held the panniers up to the fitted pannier frame to decide the best position for the mounting, once the panniers were in the desired position I drew around the inside of the mounting frame (using a very short pencil!). It transpired the ideal position was centered front to back, and with the top line of the puck 50mm from the base of the lid mounting flange. (fig. 1)

2. I marked a vertical line exactly in the centre of the pannier and a horizontal line exactly 50mm from the base of the lid mounting flange.

3. Taking one of the supplied paper fixing templates. To find the centre of the template, holding up to a window or light source I folded the template in half lining up the frame outline, then I cut a small triangle out in the dead centre on the base line (fig. 3a) and two small slits at either end (fig. 3b) Using these I could line up on the pencil lines I had drawn on the panniers, finally taping the template in this position.

 


fig. 1 Distance from top mounting flange.

 


fig. 3a

 

 

fig. 3b

 

4. I then centre-punched through the templates in the positions where holes were to be drilled. Five holes for the top puck positions and four each for the lower mounts. As is good practice, rather than drilling with the full size drill I stated by drilling smaller pilot holes, (approx 2mm)

For the smaller holes I used a 6mm drill bit although Touratech say use a 5.8mm! (as I didn't have a 5.8mm)

Note: The lower fixing puck holes are NOT square to the fixing frame, this is intentional.


Full template taped into position.

 

5. I started by fixing the lower pucks, with the lip facing downwards, bolting through the panniers using the 8mm head self tapping bolts with washers (fig. 5a).


fig. 5a

5a. Two of the bolt holes lined up with the seam weld on the pannier, due to the type and quality of weld I can't foresee any strength problem with this. (fig 5b)


fig. 5b

6. Top pucks - Although not mentioned (as far as I could tell!) the rearmost top puck needs to be fitted with the cutout facing to the rear to clear the mounting frame (fig. 6a)

The top pucks also have a rubber O-ring, this fits in the recess (fig. 6b) This I smeared with a little Silicon grease. The O-ring is located sandwiched between the puck and the pannier.


fig. 6b

These are again fixed to the panniers using the 8mm headed self tapping bolts and washers.

Fig. 6a
7. From the outside feed the metal securing tabs through (fig. 7a), from the inside of the pannier, place the wavey washer over the thread (fig. 7b) followed by the large knurled ring and finally place the M10 plastic nut over the exposed thread.(fig 7c)

fig. 7a

fig. 7b

fig. 7c

 

 
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