happy trails northwest side racks installation woes

[kliff]

Never hurts to be a memner of at least a couple of board......so, I signed on here too. A little pre-mature, as I haven't gotten a KLR yet....BUT, since signing on, finances have lined out, and in about 2 hours, I'm going KLR shopping!!!!!!! We'll see who actually is a "dealer" in the Augusta, Ga. area, and who isn't......cause I'm ole sckool, never have paid MSRP for a bike yet(35+ years) and don't intend to start now. Local sales tax is 7%, and I'm looking for an OTD price of 4900.00 on a new '06, wish me luck!

[kestrelfal]

Doing what the tech suggested (force fitting) can result in buggered screw threads and hole threads and possibly newly created self-locking fasteners. If attempted, use anti-seize compound on the threads to minimize damage. Sounds like a design and/or quality control problem. Fred

--- In DSN_KLR650@yahoogroups.com, "Jim" wrote: > > I received a Happy Trails Northwest Luggage Rack today and assumed > installation would take about ten minutes. However, when I tried to > install the rack, after loosely installing the (2) top cap screws, > the lower right was extremely difficult to start and the left > impossible because the spool was off approx. ". After struggling for > nearly an hour, I called Happy Trails, explained my situation and was > given to a tech. He said there was a simple solution all I had to > do was loosen the (6) screws on each side of the factory luggage rack > and the (2) in the middle. I really couldn't see how that would help, > but thought possibly the additional play would make things work. I > loosened all of the screws, but the lower left spool was still off > the same amount. The (4) screws that attach your rack go into (4) > stationary threaded lugs on the bike's frame, I don't see how > juggling the factory rack around would have any bearing on my > problem. The threaded hole I need to engage was still " away from > the rack spool's centerline. > > I called back, but the tech was gone for the day. The gentleman I > spoke w/ suggested starting the lower cap screws 1st. Again, I > couldn't see how this would change anything because the center to > center distance on the bike frame lugs would be unchanged but I > gave it a try. The (2) lower screws went in, but the upper left side > hole was off by, guess how much? Yep, about " - still. > > Anyone else have this problem and, if so what was your solution? > I am NOT happy with Happy Trails at this time. > > JH in OH >