Help Installing a Shad Rack (which may or may not fit) - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 18 (permalink) Old 6-13-2019, 7:44 PM Thread Starter
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Help Installing a Shad Rack (which may or may not fit)

Hi, All.
I was in Spain recently and bought from a salvage place a used Shad rack off what the guy said was a gpz500. I took his word for it. Now I'm back in the U.S. with my bike, I have the rear fairing off, and I'm trying to figure out how this thing will fit--or if it will fit at all. For all I know I have bought a rack for a completely different motorcycle. If so I don't know what bike it is.

Anyway I have been reading a post done years ago https://www.ex-500.com/12-modificati...installed.html. There are a couple of pics of how the rack is attached in one place, and a link to a shad pdf on installation, but so far, I'm can't make heads or tails of it.

I've put a couple of pics of the rack below. There are two arms. I took pics of one. ..

do any of you have any experience with shad racks? Can you give me any pointers? If the rack seems obviously to be designed for another bike, please tell me. I'm going the look the thing over for model numbers. So far no luck..



Thanks.
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post #2 of 18 (permalink) Old 6-13-2019, 11:14 PM
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I installed the Shad rack on my CTX700 a few years ago. First off, I'm a big Shad fan! They make quality cases and I prefer their brackets over Givi's and the all-expensive OEM's.

With that said, I'm not sure if those are correct for the EX but they look like normal Shad brackets. The Givi's normally have a piece of metal tubing that goes behind and above the rear fender/tail light, which I think looks like crap!
Whereas the Shads are two pieces, like you have, and then secured by attaching the top case base plate - which it looks like you're going to have to order OR they generally come with whatever top case you decide to purchase.

Again, you'll have to follow the instructions the best you can. I'm thinking you're going to have to remove the rear plastics on both sides of your EX and look for where the bracket mounting hols match up. If they don't there's either A) some kind of metal fasteners that attach to the bike somewhere else, and then to the brackets or, B) they aren't the right brackets for the EX500.
Shad makes brackets specifically for specific bikes. They're NOT universal brackets.

Hope you get it to work because you'll love their cases! I just ordered a new set of the 3P mounting system and the SH23 side cases for my brand new Honda CB650F!
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post #3 of 18 (permalink) Old 6-14-2019, 6:52 AM Thread Starter
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Thanks. I've heard good things about em too so I'm really hoping this will work. Took the plastics off last night. The trouble is (or part of the trouble): even the drawings in the pdf I found thru above mentioned post don't look a quite like what I'm seeing. I'm going to fiddle with it some more today. and search for more info.
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post #4 of 18 (permalink) Old 6-14-2019, 6:58 AM
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Any way you can post a link to the "instructions" or post a picture of them?
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post #5 of 18 (permalink) Old 6-14-2019, 9:10 AM Thread Starter
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Below is a pic of the shad instructions. You will see in the drawing the very rear end of the subframe is depicted as almost flat, and a bolt connects to the very end, fastening the rack. Well on my bike the subframe is half inch square tube, and it's hollow inside. There's nothinng for the bolt to screw in to, in there. There's another pic of that.

There are two tabs with holes in them welded to the subframe. They have rubber thingies in them. (You can see those in the pic, just below the subframe). It almost looks like it was made for the rack to fasten onto. But I think if I do fasten it there, things won't line up and the rack will sit too low. Not sure.

I'm wondering if there is a missing part, something that would fit inside the ends of those square tubes, that the bolt would screw into. If that makes sense.

Thanks again.
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post #6 of 18 (permalink) Old 6-14-2019, 12:20 PM
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Find a local hot rod shop and have them weld oin a 1/4" thick steel peice with a threaded hole to match.

1993 Teal/White EX500 6K First Street Bike
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post #7 of 18 (permalink) Old 6-14-2019, 12:53 PM Thread Starter
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thanks for the tip. I'm thinking about that, or tapping in something like this:
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post #8 of 18 (permalink) Old 6-14-2019, 1:33 PM
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If you can get a picture of the brackets placed next to where they should go that may help. But if you're eyeing it and things just aren't lining up then I'd suggest seeing if those square rubber grommet nuts would do the trick. If they work then once you put the top case base plate on it will hold the top part of the Shad brackets together so they don't pop out on ya!
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post #9 of 18 (permalink) Old 6-14-2019, 3:19 PM Thread Starter
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I believe it will fit. It just won't fit in the way those instructions suggest. The tabs that connect to the very ends of the subframe will need to be bent back about a millimeter, if that, for it to work. (Is bending the tabs back with a with hammer okay? Or is there a proper way?) And as mentioned above I will have to put something in the ends of the subframe for the bolts to fasten to. I will probably just tap in a couple of those square caps with threads in them, pictured above.

The front end of the rack attaches to rear bolt hole for those fold-away luggage hooks. I'm basically replacing the standard bolt with a slightly longer bolt that came with the rack, and which actually does fit. This connection point is completely different from the instructions, but it seems like a solid place to do it.

I am wondering what this rack was made for. It ALMOST fits perfectly, but it is quite different from the rack described in the instructions.

I am worried about clearance of the grab bar and tail of the bike. Going to look again...

Thanks again to you all. If you have additional pointers, I need 'em.
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post #10 of 18 (permalink) Old 6-14-2019, 4:09 PM
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Look and see if there are any metel 80/20 inserts that will fit peter than the plastic one. They might crack unler load of a bump in the road.

1993 Teal/White EX500 6K First Street Bike
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post #11 of 18 (permalink) Old 6-14-2019, 4:17 PM
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get a square lenght of aluminium that fits inside, drill a hole through the side and a corrisponding hole throught the frame to fit a #10 and a lock nut, drill and tap the raw metal for your bolt. But I would go find a tig welder and be done.

1993 Teal/White EX500 6K First Street Bike
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post #12 of 18 (permalink) Old 6-14-2019, 5:33 PM Thread Starter
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Thank you, sir. I was wondering about that too. I will look.
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post #13 of 18 (permalink) Old 6-14-2019, 5:36 PM Thread Starter
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and unfortunately I do not weld. I am wondering if Shad had a part that fit in the subframe and if so how they secured it there.
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post #14 of 18 (permalink) Old 6-14-2019, 9:12 PM
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Quote:
Originally Posted by castorp View Post
and unfortunately I do not weld. I am wondering if Shad had a part that fit in the subframe and if so how they secured it there.

Good luck, I think you'll figure something out! Sounds like you're on the right track to make it work.

If worse comes to worse you can always call Shad! 1-888-9SHADUS

(***Not sure the kid you wind up talking to will know what to do but it's always worth a try!)
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post #15 of 18 (permalink) Old 6-15-2019, 12:32 PM Thread Starter
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Thanks. May call them but I have very little hope of getting anyone who can tell me anything. AFter all I don't know what bike the thing was made for, what model it is (no markings anywhere except for Shad logo), and it looks old. Really old. Did the first generation ex500/gpz500 have a different subframe?


Still not sure what I'll do. Welding threaded caps/plugs on the ends of the subframe as Kevin has pointed out is obviously first choice, but I do not weld and I'm kinda reluctant to spend much money at a shop on an old rack that has seen better days... At the same time the more I think about those nylon/plastic threaded inserts, the less sturdy they seem. Maybe the the aluminum bar option but that would involve putting a threaded hole in the end of the bar as well as drilling through the frame....
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post #16 of 18 (permalink) Old 6-16-2019, 8:40 AM Thread Starter
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I have it on. Thanks to you all. I hope to be putting a base plate and box on in a couple of days.
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post #17 of 18 (permalink) Old 6-17-2019, 7:15 AM
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So...how'd ya do it? And it appears to be rubbing up against the rear cowl from the picture. Glad you got it mounted. What case are you going to put on there?
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post #18 of 18 (permalink) Old 6-17-2019, 6:25 PM Thread Starter
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no, not touching the rear cowl. Just clears it on either side, but doesn't get in the way of the indicators--so as far as that goes, it's all right.

I made a plugs just big enough so that they fit snug in the square steel tube of the subframe. And I made em a bit long, so they go deep. I drilled holes in the plugs, then put the bolts through, then put the nut on the end. I tapped them into the subframe, then tightened the bolts, which caused the plugs to swell. So it holds it very snug. I then put some heavy duty zip ties fastening the rack to the frame, just in case one of the plugs fails. The ties are hidden by the rear fairing. I woudl have rather done it the way Kevin suggested but I feel like it would have been difficult (for me, anyway) because the rack really is just a milimeter or two too short, which causes the bolts to go into the ends of the subframe and an angle, but with the plugs it allowed for a little play until I tightened it down. I am going to keep an eye on it, make sure all is okay, especially during the first few rides. But right now it feels very snug. I can grab the rack and push down hard and the rear shock compresses but the rack doesn't give at all.

Putting an Emgo box on it for now. And that's going to require a little "creativity" too. The base plate is just bit too narrow. and I want to fasten the thing through the official holes, rather than drilling, because those look reinforced. I'm going to get a thick black plastic cutting board, trim it down to the right size, make that the base base plate.

I am doing this, as maybe you can tell, on a budget.
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