ADV Lite Motorcycle Build Series: Kawasaki KLX300 Rear Rack
- Randy Reek, The Great Out There
- 43 minutes ago
- 3 min read
This series will follow the transformation of the stock KLX300 dual sport into a capable "lite" adventure touring motorcycle!
The Kawasaki KLX300 is a popular dual sport known for its rugged construction and reliable engine. There is a HUGE difference between a stock dual sport motorcycle and one equipped for extended touring.
I won't own a motorcycle that can't be outfitted with a rear cargo rack! Thankfully, due to the popularity of the KLX300, there are plenty of aftermarket options.
I don't always use rear panniers for my ADV travels. Most of the time I only need a top bag for my clothes, tools, and supplies. This is especially the case for short "ADV Lite" trips, or extended trips when I am not camping but staying in motels.
However, when selecting the rear cargo rack for my "ADV Lite" KLX300, I chose a model that included the rear side supports for panniers.
My preference is smaller, "rackless" panniers. Yet I didn't want to be limited at some point in the future if larger panniers were necessary for added gear and clothing layers - for example, another trip to Alaska!
The installation shown here included the mounting cross-brace for the side racks - even though I did not install them at this time. Likewise, the link for this rack includes BOTH the cargo rack and the side racks - although the top cargo rack is available separately.
There are numerous rack options for the KLX300. MOST are heavy, welded, tubular steel. The one I chose was a flat platform of ALUMINUM, precision cut by CNC, and then powder-coated black. This saves a few pounds over the steel alternatives. (The side racks that I also purchased ARE welded, tubular steel - although I might never use them!)
Here is a video that shows the finished installation of the rear rack on the ADV Lite KLX300:
This video can't show the aggravating process of stacking the components to attach the rack. The rack bolts DOWN through the bracket that is used to attach the side racks and two spacers. The only way I could stack these sets of pieces was to insert a bolt from below and hold it in place with a piece of tape.
With the spacers and cross-brace suspended, I lined up the top rack and slowly, carefully pushed each mounting bolt down through the stack, wiggling each piece into alignment until I pressed the bolt through the subframe. Each mounting bolt is secured by a nut on the underside.
The rack attaches to the mounting points that secure the saddle. Again, you need to insert the bolts through the rack, spacers, and tabs on the saddle base before tightening the longer bolts - which are provided.
You can see that the main mounting bolts create exposed button heads above the rack. I wanted a flat surface to support my soft tail bag. So I cut a HDPE cutting board to fit the rack (and RotopaX - see below), then drilled two holes to match the location of the button head bolts.
I also drilled two holes that match the mount for my 1.75-gallon RotopaX gas can. This is all I need for the rare occasions when I'm travelling out West with long stretches between refills. The 1.75-gallon can of spare fuel extends my range by over 100 miles - and costs less than one-fourth that of replacement gas tanks!
What do you think? Leave your comments below. Then subscribe to the GreatOutThere.online blog for the next installment in the KLX300 ADV Lite series!
Here is the link for this KLX300 cargo rack, including the optional side pannier racks: https://amzn.to/4pKsddn
