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Suzuki DR200: installing a top-box

A black hard plastic case with Overland Journal and Storm Case IM2600 labels sits on a surface. Part of a Suzuki DR200 motorcycle is visible in the background, suggesting possible top-box installation or other motorcycle accessories. A red and white sticker decorates one corner.

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):

An empty, open black plastic storage box—one of the essential motorcycle accessories—is attached to the back of an orange Suzuki DR200. The box’s interior is scuffed and has crosses molded into its bottom surface.

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:

View of a Suzuki DR200 cargo rack, perfect for installing top-box motorcycle accessories, mounted above a yellow fender with two orange turn signals and a red taillight; part of a white vehicle tire appears in the background.

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:

Close-up view of a Suzuki DR200 rear rack, showing a metal plate secured with a bolt and nut—perfect for installing a top-box. An orange rear turn signal and part of the yellow motorcycle body are also visible, highlighting essential motorcycle accessories.

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!

An open, empty black hard plastic storage case is mounted on a Suzuki DR200, with the lid raised and the interior visible—perfect for top-box installation and essential motorcycle accessories.
A close-up, top-down view of a Suzuki DR200 motorcycle with a blue seat and a large black top-box installation on the rear. Part of a white vehicle tire is visible in the background, highlighting practical motorcycle accessories.

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. His polar travels include two vehicle crossings of Antarctica and the first long-axis crossing of Greenland. He lives in Prescott, Arizona IG: @scott.a.brady Twitter: @scott_brady