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Some people that dual sport their dirt
bikes may also want to carry a passenger, or at least I do.
There are clamp-on and bolt-on type passenger pegs available.
Obviously the clamp-on type would not require additional brackets if
there is a place on the subframe or frame rail to mount them. I
obtained a good used set of passenger pegs from an XR650L, and these
required brackets to be welded to the subframe of my XR400R, as
shown below.
Here is everything
used for my passenger peg installation:
- Scrap piece of steel (I used
something fairly thick)
- Passenger pegs (I got a used
set from an XR650L)
- Mig or arc welder and
moderate welding skills (this was my first time)
- Drill, bits, and a tap the
size of the bolts used (tap is optional)
- Primer and paint the color
of the frame
| 1. |
The first step is
to sand the area of application. On the subframe of my bike, just below the elbow in the frame, is where
I mounted my passenger pegs. |
| 2. |
Next, I found some
steel to use as mounting brackets (x2). I used some scrap lying
around, it was around 9 Gauge. Strip off any paint and clean
the metal of any grease and oil. |
| 3. |
I planned out my
brackets by making any necessary measurements and hole
markings. It may be easier to drill all necessary mounting holes
in the bracket
before cutting them out. The holes required for my XR650L
passenger pegs were 5/16" threaded. A few options for
mounting the pegs are: 1. Drill bolt holes for clearance
fit and use nuts on backside. 2. Drill and tap holes to the
thread size and pitch of the mounting bolts. (I went with this
method) 3. Drill bolt holes for clearance fit and
spot-weld nuts to the inside
of the brackets. |
| 4. |
I cut the mounting
brackets to their final size before welding. Mine turned out
to be 1" x 4". |
| 5. |
Now comes the fun
part. After prepping both surfaces by sanding and cleaning, you
could either tack weld or use a clamp to hold the brackets on
the rail. Weld the brackets, both on the front and back side (as
shown here). Don't
forget to get the top and bottom as well. My welds are not
that nice looking, as this was my first time ever using a mig welder. |
| 6. |
Clean up the welds
with a die grinder and stones. |
| 7. |
Drill the passenger
peg mounting holes if you have not already done so in step 3. |
| 8. |
Prime
and paint the area to avoid rust and corrosion, and so it
looks good. |
| 9. |
Install the
passenger pegs with the bolts of choice. Mine were 5/16" Fine thread stainless steel bolts and
nuts. It is also a good idea to use locknuts and/or thread
locking compound. |
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CLICK TO ENLARGE
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Flat steel stock
for brackets |
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Bracket welded to subframe |
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Close-up
of passenger peg |
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Passenger pegs installed |
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A word of caution: You must keep in
mind that the weight of a second rider will put more stress on the
suspension, motor and drive-train, so extreme caution should always be used when riding
with a passenger.
Disclaimer: The views and procedures expressed herein do not necessarily
reflect those of 4Strokes.com. As with any modification there could
be adverse effects, which could cause damage or harm to the
motorcycle or yourself. 4Strokes.com assumes no liability in how
this information is used.
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