How To: Secure Genuine Suzuki Pannier from opening on the go

[kevshek]

EDIT; goes without saying, you need to listen for that CLICK when closing your panniers

I read a few threads where original panniers have opened whilest on the move. Now that its in my head, I can't get away from it, so today I had a go at looking at the lock system to figure out a fix. Surprisingly, there is a really simple fix for it.

Heres the background to the problem.
The Suzuki pannier lock using a single latch system, which appears to be substantial enough. The latch mech is covered by this cover, held by 3x 15mm screws. This is where it goes wrong........


As soon as this cover is removed, the latch comes/pop out! So in theory all your gear is held by 3x 15mm screws! and these are just screwed into plastic posts (which my lower 2 are cracked from factory!


When the covers on, this raised edge keeps the latch in place.



Think about the pressure on them. Say if you jam pack you pannier, and your going for a long ride, somethings going to give. But fear not....... kev to the rescue.

So heres what you do, remove the cover. and Measure 45mm in from the edge, and 30mm up to the top edge like so. Repeat for the other side and send a 3mm drill through the marked holes.



Now replace the cover momentarily, but without the latch. Heat up an old screw driver around 2-2,5mm dia.


Send that through both side where the holes are. This will give/melt you a small pilot hole into the base of the locking system.


WHILE YOU HAVE THE COVER OFF, ITS WORTH WHILE SECURING THE BOTTOM NUT ON THE LOCK BARREL.

To do this, simply remove the 10mm nut at the bottom of the barrel.


There are 3 washers, they go back in order from left to right.


Just dab some loctite onto the protruding threads and replace the nut.


Once that ground work is done, replace the latch, making sure you first unhook the spring from the top, and insert the leg along the ledge on the side of the base section.


Next locate the pivot posts either side of the latch, keep pressure applied to the latch and hook the spring back onto and over the top of the latch.


Now carefully replace the cover, passing your finger/latch through the cover plate. Remember to retain that pressure of the latch will pop off. Secure the cover with the 3 screws you removed.

Now find yourself a couple of 15mm self tapers like so


Screw them into the new holes you've drilled.


Jobs a guddun! Now you have latteral/shearing force to contend with, before the latch can come apart, not just the original 3x 15mm screw from factory. You can go further and add more if you wish, but this should surfice.

TIP: Now that you know how its done, you could actually skip the whole cover and latch removal process, just mark the hole location as best possible, and send a hot 2mm - 2.5mm screw driver through the cover and base section and insert your screw. You may need to send it through at a slight angle, so you can get you hand and stubby screw driver in there to tighten it.

[Piglumps]

I haven't got the GT panniers but I have heard the tales of them popping open. Your solution is well though and well documented. Top job!  

[Sven]

Nice work.

Think I took the lazy way of doing it though.
I bought 2 bungee straps @ £1.99.
Then hook them around the pannier ( top rail to bottom rail)
Sorted

[kevshek]

It gets even easier mate, I've just done the othr side, it litterally takes 5 mins! now you know where to poke the hole. ooo-er

[snowy]

Hi

Well done that man. Will do the same to Mrs Snowys although I will still put a strap round the pannier and the pannier frame to stop them falling off the bike totally as using the same key turned one way to open and the other way to remove keeps me awake at night.

Still don't know what that twisty Knob does that's marked "open, close" inside the box as it seems to make no difference which position its in.

All you need to do now is to stop them falling over when you put them down off the bike, all I can think of is to screw blocks onto the outside, not pretty but should work.

Obviousy designed some twot in an office whose never used a pannier on or off a bike, a bit like all those Givi/Kappa systems, we've got gravity on planet Earth, use it don't fight it.

Rant over for now. Going to jet wash the patio as we live in non hosepipe ban area (I think)

[matchless]

If you have the lock in bits take the nut off that you can just see  in Kev's picture 4 and loctite it, otherwise the plastic lever it retains will at some time come loose and you will have to force the lock to get the box open.

[kevshek]

Do you mean the large nut retaining the lock barrel? Or the one on the end of the lock barrel holding the cam on?

[matchless]

The one holding the cam on.

[kevshek]

Yeah, well worth sticking some loctite on there. I think I'll go dp that shortly. Best be safe than sorry.

[Locky]

What a shite idea from Suzuki . Well done for explaining the fix , I'm sure most will copy it ..

[kevshek]

First post updated with some info re securing the nut.

[Bumhead]

Nice work.

Think I took the lazy way of doing it though.
I bought 2 bungee straps @ £1.99.
Then hook them around the pannier ( top rail to bottom rail)
Sorted

 

[Juvecu]

The plastic knob thingy that turns 90 degrees is for locking the mechanism once the pannier/topbox is on the bike. That way you can't accidentally unlock the box from the rail by turning the key the wrong way because the latch won't move. If they aren't working it's probably because they were forced at one time or another and broke internally rendering them useless. When I had the GT boxes, 2 of them worked (one pannier and the top box), but the other pannier's didn't (bought it like that.)

I never had any issues with boxes falling off if I made sure they clicked on properly. Then again, I did make sure the latch screws and stuff were solid and stayed in so that probably explains it in light of what Kev found.

[kenww]

Had my used GT a week and had to repair top box lock,opening cam is plastic,Think I might sell them and fit givi,how ugly is the rack.
Complete crap

[Dave the Dude]

As a"newbie" I apologise for asking such a simple question but here in Thailand Suzuki offer a "boxy" ali pannier and a more rounded plastic type.
Does this locking set-up/ problem apply to both types of luggage?????

[tallpaul]

I think it is just the rounded type. Certainly the pictures above are from the rounded GT type. Which reminds me, I must get mine modified!

[Juvecu]

The boxy type is from a different manufacturer and won't have this particular problem.

[Dave the Dude]

Thank Paul & Juvecu

[kwackboy]

Personally I've had no problems with the catch on both panniers and since I've owned the bike I've been on plenty of trips, this still doesn't stop me from stretching a net bungie around them both ..
To be honest I think I would do the same to any side loading panniers . Good tip though  

[geronimo]

Yep, had my new 2014 1000 Vstrom less than 2 weeks when I got home and found the lock and barrel from the tiny top box had disappeared!
 Thankfully, I was going to replace it with a nice sized Givi box anyway.
 The top box and panniers (stock on the Adventure version) are so small as to be a token gesture.
 Apart from the tiny luggage problem, I love the bike and find it hard to criticise.