Page | 3
Tusk Aluminum Pannier Boxes
INS
TALLA
TI
O
N
INS
TRU
C
TI
ONS AND
I
N
FO
RM
A
TION
Pannier Mounting
Note:
Most universal type pannier boxes can be mounted
to the tusk pannier racks. Always refer to the instructions
included with the boxes you are mounting.
1.
Install the mounting plates to both the left and right side of
the pannier racks (pull the pull-pins back and make sure they
engage correctly into the mounting plate).
2.
With the mounting plates in their proper position, hold up the
panniers to the bike to find the optimal position for rider
comfort and look. It is a good idea to have a friend hold one
side up at a time while you sit on the bike to make sure you
are comfortable with the position.
Note:
When positioning the pannier, keep the passenger’s
leg, foot, and passenger peg in mind if you ever plan on
having a passenger).
3.
Once the optimal position is found, mark the location of the 7
mounting holes that will be required (this is best done while
your buddy holds the box in place and you mark the holes
with a marker).
4.
Carefully set your box down with the backside up. Remove the
mounting plate and set it on the box to make certain your
marks are aligned correctly (Measure twice, drill once!). Drill
the holes just big enough to fit the 8mm mounting bolts
(11/32” bit).
5.
Drill one pannier at a time. Once the first pannier is drilled,
you may be able to use it as a template for the other side.
Put the 2 pannier boxes back to back with the lids removed.
Mark the pannier that hasn’t been drilled through using the
holes in the drilled pannier. Again, using the correct
mounting plate, double check the marks. Once the drill
marks are correct with the mounting plate, confirm fitment to
the bike and drill the holes.
6.
Bolt the mounting plates to the panniers using the button head
allen bolts. Make sure the internal box support bar is used
(flat bar) on the top 3 mount bolts (M8 x 20mm). Washers
will be used on the other mount bolts (M8 x 25mm). The bolt
will go in through the mount plate, into the box, through the
internal mount bar, and into the nuts on the top 3 bolts. The
bolts will go in from the inside of the box on the lower bolts,
the nut will rest outside on the mounting plate.
Note:
The internal box support is critical for this pannier
rack system. If not used, the weight of the box and gear
will bend the mount plate and can lead to further rack
damage and failure.
