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Suzuki DR200: installing a top-box

The Rear Rack from Cycleracks provided for a great platform for mounting a top bag or box, as well as panniers. I think I will use a combination of soft & hard luggage, and for now will mount a top-box in the rear. I decided to use the same Stormcase iM2400 that Scott Brady used on his Trans America Trail trip that he did on his KTM 950 Adventure (since the box already had some holes drilled into it):

I scrounged up some scrap metal to fab the straps, and rounded up some hardware from our bolt bin. After making the aluminum straps, I drilled 4 new holes into the box (and put tape over the previous holes to prevent ingress of dust):

I then placed several wraps of tape on the rack, to prevent metal-on-metal vibration and reduce the rattling of the box where it contacts the metal rack:

Since this motorcycle “buzzes” quite a bit, I decided to use both lock-nuts and lock-washers in hopes that the hardware will not come loose:

After a few hundred miles with the case on, it hasn’t come loose at all. It provides a good storage area (dust & water-proof), with the ability to place two locks on it for added security. If you already own a Pelican case (or similar), and don’t mind drilling a few holes in it, with about 45 minutes of work this is a very inexpensive way to add hard-luggage to a dualsport motorcycle. It should serve me well on my upcoming adventure to Baja!


Scott is the publisher and co-founder of Expedition Portal and Overland Journal. His travels by 4WD and adventure motorcycle span all seven continents and include three circumnavigations of the globe. He lives in Prescott, Arizona