Hello everyone. I am wanting to build some custom pannier racks but was hoping someone would be able to provide a couple measurements for me as a starting point. The main dimensions I need are the height and width of the main rectangle. I have not purchased soft bags yet but would like to build general sized racks that I can adapt to whatever bags I end up with. I was tempted to just buy the Tusk racks but I am not a fan of a few of the features and design. Thanks in advance.
FlightNurse1290R
24.5cm x 34.75cm that is the closest I can get on the touratech rack. I am guessing they have a very non-standard size to have this be 'proprietary'; it is difficult with the rounded edges, so this is by 'eye'.
I give you kudos on trying to build your own and yes, these are expensive for a few bent pieces of metal, but you are paying for the engineering. I have the Zega Evo X for the 2022 SAR, so this measurement is only on the side that is flat. I choose to purchase these as I like how they cut back in on the silencer side, giving a symmetrical look.
I did have to modify the black plastic rack cover pieces as it looked a little funny with the bolts exposed and wish they at least came with a template of where to cut as I over cut a few times. I may order a new set and tape where I now have a gap, so I can get these covers to fit more tight. There is still the problem of taking some of the 'girth' off behind where the frame mounts that has them stick out a little. I know it is a tangent, but wish they just made a replacement cover to it has a good fit and finish to a set of panniers that are $2k USD.
Good luck with your build as the angles for the bars to connect to between the passenger foot pegs and their footpeg mount seem to be a very weird angle. Again, paying for the engineering.
Are you going to buy the branded pannier and just want a home-built frame? Because I believe the panniers from touratech are $1000 ($500 ea).
I give you kudos on trying to build your own and yes, these are expensive for a few bent pieces of metal, but you are paying for the engineering. I have the Zega Evo X for the 2022 SAR, so this measurement is only on the side that is flat. I choose to purchase these as I like how they cut back in on the silencer side, giving a symmetrical look.
I did have to modify the black plastic rack cover pieces as it looked a little funny with the bolts exposed and wish they at least came with a template of where to cut as I over cut a few times. I may order a new set and tape where I now have a gap, so I can get these covers to fit more tight. There is still the problem of taking some of the 'girth' off behind where the frame mounts that has them stick out a little. I know it is a tangent, but wish they just made a replacement cover to it has a good fit and finish to a set of panniers that are $2k USD.
Good luck with your build as the angles for the bars to connect to between the passenger foot pegs and their footpeg mount seem to be a very weird angle. Again, paying for the engineering.
Are you going to buy the branded pannier and just want a home-built frame? Because I believe the panniers from touratech are $1000 ($500 ea).
I have the Tusk racks they are OD 12.5" x 10" (w/h).
The Tusk racks are actually OK, except the rear cross piece was not updated for the 19' 1290 tail. I went out to RM/Tusk with photos and got total dead air.
It looks like KTM changed the 1290 rear tail and RM (who I believe own Tusk - or control several Tusk product lines) never updated it.
You can simply invert the rear cross piece - however if you have a suspension failure while loaded down the chances of that bar when inverted hitting the rear tire is very real. That could be bad to catastrophic.
The fix was to modify the cross bar itself by cutting and welding (any muffler shop can do it) and then using spacers to push it rearwards. Yea I could have sent them back - but the cost was right, they are very heavy duty and even with a few bucks for the modification it was still way cheaper than going a different route.
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![Image]()
The Tusk racks are actually OK, except the rear cross piece was not updated for the 19' 1290 tail. I went out to RM/Tusk with photos and got total dead air.
It looks like KTM changed the 1290 rear tail and RM (who I believe own Tusk - or control several Tusk product lines) never updated it.
You can simply invert the rear cross piece - however if you have a suspension failure while loaded down the chances of that bar when inverted hitting the rear tire is very real. That could be bad to catastrophic.
The fix was to modify the cross bar itself by cutting and welding (any muffler shop can do it) and then using spacers to push it rearwards. Yea I could have sent them back - but the cost was right, they are very heavy duty and even with a few bucks for the modification it was still way cheaper than going a different route.
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