http://www.touratech-usa.com/instl/pannier_mounting.html
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 Draw a line 68mm (= 2-11/16 inch) from the top of the pannier top edge. The puck must be mounted below this line or the locking knob will interfere with the inner sealing edge of the pannier. We used a permanent marker on the bare aluminum (it rubs off). Please understand why this is necessary and verify it yourself if you are anywhere near the 68mm line as use of these instructions are at your own risk. Click this LINK for some notes on the LOWEST recommended position. |
 Wrap some tiedowns around the boxes tightly so the friction alone holds them to the racks. You can slide them up and down to get your desired positioning. You may want to draw some straight lines on the pannier for reference (draw first!). In the photo we are using one set of towdown utility straps connected together. It's better to use two separate straps; each holding one box. Otherwise, moving one box can affect the other. |
 Get some double-stick foam tape from a large department store. It's used for hanging stuff on the wall. The soft foam tape is necessary because the pucks are not perfectly flat. |
 Put as much of the tape as you can on the puck. Trim it to the edge of the puck. The lower pucks need more tape than the upper pucks. After you have your panniers positioned where you want them, cram the four pucks into their corners of the racks and press them down so they bond well to the aluminum. See the next photo before you start. |
 Decide on the orientation prior to placing the pucks. Vertical or Horizontal retainier orientation depends on where you decide to position the pannier relative to the supports. Use your pen and make some marks on the pannier showing this orientation. Also label each pannier "left" or "right". The lower pucks are skewed to allow easier disengagement of the pannier from the rack. The angle measurement is not important, just make it look something like the photo when you place the pucks. |
Carefully remove the boxes from the racks with their taped-on pucks. Press the puck down hard so it won't move as you drill the 3/16" hole (or 4.75mm), using the plastic puck as a drill guide. be careful not to ovalize the screwhole in the plastic puck because it needs to tightly accept a self-tapping screw. |
 Remove all the pucks and the foam tape. Enlarge the holes in the box to 7/32 (or 5.5mm)" which allows the self-tapping screws to pass thru. |
 De-burr the holes on the outside of the pannier so the puck fits tightly. |
 Install the upper puck with 2 or 4 screws, then drill the 10mm hole. We used a 3/8" drill bit (=9.5mm). You will file the hole to a perfect center, so don't worry about the center, except don't allow the drill to chew on the plastic. |
 Then we opened up the hole to 10mm with a round file. It was easy, only a few strokes of the file. The file does not cut the plastic, rather it glides on the plastic when matched diameter is reached. Check the diameter by poking the 10mm retainer bolt thru the hole. File until it pokes all the way thru with no resistance. Then remove the puck and de-burr the hole. |
 Put the pannier retainier thru the puck, add the o-ring, and (we sealed it with black silicone). Place the puck on the pannier in the proper orientation and install the four self-tapping screws. |
 Add the wave washer as shown. |
 Looking at the retainer knob, inside the panner. Screw the retainer knob onto the retainer bolt. The nylon cap-nut covers the threaded end. |
 For custom installations using the Touratech system, (building your own racks) you will need these parts for one side. The Rectangular hoop is 051-0300 (18mm). The other parts are from one "Pannier mounting kit 18mm" 053-0020. |
