Pelican Box on KLX250S
 

In a previous thread questions were asked about the storage box on my KLX.
It's a Pelican box, model 1200. I'd say it's about the perfect size for my needs, mainly carrying tools. Have had it on for about 600 miles, most of which have been off road on trails. It's solid as a rock and have not had any problems even with a full load of tools. Installation was pretty simple with 3 rubber coated "P-clamps". Here are some pics...

The Pelican products are generally expensive (~$40 to $50 for the 1200) and there are some other less expensive boxes out there. Here's a link to an alternative and how it was mounted:

http://www.cyclepathic.com/klx/klx_StormCase.htm

Your basic Pelican 1200 box...
[IMG]http://i463.photobucket.com/albums/q...x/IMG_7504.jpg[/IMG]

[IMG]http://i463.photobucket.com/albums/q...x/IMG_7503.jpg[/IMG]

[IMG]http://i463.photobucket.com/albums/q...x/IMG_7488.jpg[/IMG]

Here's the key to mounting, the "P-clamp". I used an UMPCO #S325G8, 1/2".
Lowes sells a similar part in their specialty hardware section.
[IMG]http://i463.photobucket.com/albums/q...x/IMG_7513.jpg[/IMG]

To mount it I measured distance between outer bars on the rack and the distance to the rear of the rack then made marks on the bottom of the box to guide drilling of the holes.
[IMG]http://i463.photobucket.com/albums/q...x/IMG_7496.jpg[/IMG]

I used 1/4-20 plated bolts, flat washers on the inside and interference type lock nuts on the outside (this type nut will not loosen from vibration).
[IMG]http://i463.photobucket.com/albums/q...x/IMG_7489.jpg[/IMG]

[IMG]http://i463.photobucket.com/albums/q...x/IMG_7491.jpg[/IMG]

[IMG]http://i463.photobucket.com/albums/q...x/IMG_7492.jpg[/IMG]

[IMG]http://i463.photobucket.com/albums/q...x/IMG_7495.jpg[/IMG]

Here's the tool load that I typically carry. It changes occassionally depending on where I'm going and who I'm with...
[IMG]http://i463.photobucket.com/albums/q...x/IMG_7505.jpg[/IMG]

[IMG]http://i463.photobucket.com/albums/q...x/IMG_7510.jpg[/IMG]

And for good measure I keep my DMV registration card under the foam in the top...
[IMG]http://i463.photobucket.com/albums/q...x/IMG_7502.jpg[/IMG]

Looks Great.
Thx for the step by step tips

I really should do one of those for my KLX. Its really hard to order take out and not end up with it smashed inside the coat. Plus, I have been riding tooless since I had the KLX. Not a good thing if I needed just a screwdriver.

Looks good. I like the pelican cases as well (you get what you pay for). I carry a laptop in a pelican case in my work truck. Some good cases.

Too lazy to do a search on what deej used for his. Seemed to work out well for him as well.

I think Deej used the next size up. Same footprint but a little taller. I am thinking of putting one on mine with some kind of semi quick detachemet setup. I was thinking of welding some nuts into the rack so all I need to do is screw in three bolts from inside the case That project is a while off I still have other bike projects first.
Cheers Jim

Nope mine is the 1200 also, in black. Installed it just a couple of months after I got the bike in November of 05 nearly 4 years ago, I carry anything from extra gas in it..

Attachment 17756

A 25 ft tow chain...LOL
Attachment 17757

An 8 piece box of chicken
Attachment 17758

A 90 piece bag of pizza rolls...:)
Attachment 17759

I can also slide the bar of the Stihl 009 saw right under it, for those pesky trees across the trail. ;)

Attachment 17760

Attachment 17761

Yep in 13,000 miles its only been off the bike once, and that was to make room for all my stuff on the trip to Canada in 08.

Attachment 17762

20 minutes after reading this thread I order one of these for $32.50 shipped.
http://www.adorama.com/STCIM2050BK.h...62624406265112

Great setup,thanks for the thread

One side note, I did have to replace the clamps a couple times over the years. Our little hardware store here in our "one stop light town" stocks the Adell rubber clamps. ;) That's a lot of vibration on the back on trails and gravel roads. So if you find the clamps, get 6 not 3, that way you are ready when the time comes.

Wow!...some of the loads pictured here seem a little extreme for what appears to me to be a fairly wimpy subframe design. I love my '06 KLX, but it doesn't look to be much of a mule back there for subframe sturdiness. On the other hand, that doesn't really bother me, because that's why I went to this bike over my KLR650. I wasn't looking for a U-Haul...I was looking for more of a two-seater sportscar...LOL!

I just use a large bicycle rack bag, so that I'm not tempted to overload the rack/subframe. I split up my tools and supplies between the rear bag and a front fender bag and a number plate bag. The rest goes in a large hydration pack with my water. I realize that most riders aren't running rough off road conditions with all that stuff on the rack, but it seems that any amount of running over time with some decent weight will allow bumps and vibration to work its damage on the subframe. I really watch what I carry in my rear rack bag and try to limit the weight.

I like the Pelicans. I've got one on my KLR:

http://inlinethumb06.webshots.com/42...600x600Q85.jpg


However, I prefer a soft bag on the KLX:

http://inlinethumb42.webshots.com/43...600x600Q85.jpg

This one is a Moto-Fiz. Kind of a goofy name, but it is a great bag.

It has some small outside zippered compartments and a large zippered main compartment. It has an overflap with a zippered mesh pocket and some shock cord on top that can be used to attach more items if necessary. Also there are two water bottle holders.

They are made in Japan. Aerostich is the only US importer.

Ron