6 Auxiliary Battery Trays For Dual Sport Setups For Touring

Outfitting a dual-sport bike for long-distance touring often requires moving beyond the stock electrical limitations. Relying on a single battery to power GPS units, heated gear, and auxiliary lighting is a recipe for being stranded miles from the nearest pavement. Adding an auxiliary battery tray ensures that your bike remains a reliable partner, even when the terrain demands more juice than a standard system can provide.

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Touratech Aux Tray: Best For Heavy Touring

Touratech gear is synonymous with the rigors of global overland travel, and their auxiliary tray reflects that reputation for durability. This unit is built to withstand high-mileage abuse and the constant vibrations of washboard roads that often shake lesser components to pieces. If the bike serves as a primary mode of transport for months at a time, this is the hardware to rely on.

The design prioritizes structural integrity over weight savings, making it an ideal choice for heavy adventure bikes like the BMW GS or Africa Twin. It provides a secure, vibration-dampened cradle that prevents the battery from shifting during aggressive off-road maneuvers. While it carries a premium price tag, the peace of mind offered by its robust mounting points justifies the investment for serious tourers.

AltRider Universal Box: Most Durable Option

For those who prioritize modularity and brute-force strength, the AltRider Universal Box stands out. Constructed from heavy-gauge stainless steel, this enclosure offers superior protection against both physical impacts and the elements. It is designed for riders who frequently cross riverbeds or navigate rocky sections where under-seat space is at risk.

The universal nature of this tray allows for significant flexibility when installing different battery sizes, though it requires a bit more customization during the initial fitment. It is best suited for riders who are comfortable with light fabrication or mounting adjustments to achieve a perfect fit. If durability is the only metric that matters, this tray is the definitive choice.

JNS Engineering Box: Best For KLR650 Builds

The KLR650 has a legendary reputation for simplicity and longevity, and the JNS Engineering battery tray adheres to that same philosophy. Specifically engineered for the unique chassis dimensions of the KLR, this tray eliminates the guesswork often associated with universal fitment kits. It tucks neatly into the cramped quarters of the bike without requiring permanent modifications to the frame.

This tray is the go-to for riders who want a “bolt-on and go” experience without sacrificing quality. The construction is precise, lightweight, and specifically oriented to keep the battery centered and stable. For KLR owners looking to add heated grips or charging ports for long highway stretches, this specific kit removes the frustration of trying to shoehorn generic parts into a bike not designed for them.

Antigravity Battery Tray: Best For Lithium

As lightweight lithium-ion batteries become the industry standard for performance dual-sports, the Antigravity tray provides the necessary infrastructure to manage them effectively. Lithium batteries require specific mounting hardware to prevent movement and to manage the slight differences in form factor compared to traditional lead-acid equivalents. This tray is precision-engineered to hold these high-discharge batteries firmly in place.

Choosing this tray is the smart move if weight reduction is a primary goal for the build. It is stripped down to the essentials, avoiding unnecessary bulk while maintaining high-tensile strength. If you are upgrading to lithium, do not try to make do with a standard tray; this unit ensures the battery terminals and casing remain intact, regardless of the terrain difficulty.

SW-MOTECH Power Bracket: Easiest To Install

Installation anxiety is a common barrier for riders looking to upgrade their electrical systems. The SW-MOTECH Power Bracket minimizes this by utilizing existing frame mounting points, significantly reducing the time spent in the garage. It is an ideal entry point for riders who prefer to spend their time riding rather than fiddling with custom fabrication.

The beauty of this design lies in its simplicity and clean integration. It keeps the wiring runs short and accessible, which makes future maintenance or troubleshooting a much faster process. If the priority is a quick, reliable installation that respects the factory integrity of the bike, the SW-MOTECH bracket is the clear winner.

MotoMinded Battery Tray: Best For KTM Bikes

KTM bikes are built for performance, often resulting in extremely tight packaging around the battery compartment. MotoMinded understands this constraint intimately, creating trays that maximize every millimeter of available space. Their designs are sleek, minimalist, and perfectly adapted to the aggressive seat lines and subframes of modern KTM dual-sports.

Riders on KTM platforms often struggle with finding space for extra gear, but this tray solves that issue without forcing a compromise in structural support. It is the preferred choice for riders who demand that every ounce and inch of their bike serve a specific, high-performance purpose. If the goal is a race-ready, clean build, look no further than this solution.

Where To Mount Your Aux Battery For Balance

Placement of an auxiliary battery is as much about handling as it is about convenience. Mounting the battery as low as possible and as close to the bike’s center of gravity—usually near the swingarm pivot or under the seat—prevents the machine from feeling top-heavy in slow, technical sections. A high-mounted battery can make a bike feel sluggish and “tippy” during tight switchbacks or mud crossings.

• Under-seat: Ideal for keeping weight low, but check for heat clearance from the exhaust.
• Near the airbox: Good for center-of-gravity, but ensure the battery is shielded from engine heat.
• Behind side covers: Excellent for accessibility, provided the mounting tray is robust enough to handle the leverage.

Protecting Your Battery From Trail Vibration

Off-road riding generates high-frequency vibrations that can loosen terminal connections and crack battery casings over time. Always use high-density, closed-cell foam padding between the battery and the tray. This acts as a dampener, absorbing the jarring impacts that occur when hitting hidden rocks or crater-sized potholes at speed.

Avoid rigid mounting methods that transfer energy directly into the battery housing. Instead, use rubber-lined straps or secondary vibration-dampening mounts if the terrain is particularly rough. Secure terminals with thread-locking compounds, but ensure they are still accessible for emergency disconnection if a short circuit occurs in the field.

Smart Wiring Tips For Your New Power Setup

The wiring is just as critical as the tray itself. Use marine-grade, multi-strand wire, which is more flexible and resistant to the constant flexing that occurs during off-road suspension travel. Always incorporate a high-quality fuse block immediately after the positive terminal, ensuring that every accessory circuit is individually protected.

• Solder vs. Crimp: Use quality heat-shrink crimp connectors instead of solder for high-vibration areas; solder can become brittle and snap over time.
• Routing: Keep wires away from heat sources like the exhaust and moving parts like the rear shock or chain.
• Grounding: Ensure all grounds are attached to a clean, metal-to-metal chassis point to avoid intermittent power losses.

Maintaining Your Aux Battery Between Trips

Even the best battery setup will fail if neglected during the off-season. If the bike remains parked for more than a few weeks, use a trickle charger—specifically one designed for your battery chemistry—to prevent sulfation or deep discharge. Regularly inspect the battery tray hardware to ensure that no bolts have vibrated loose since the last adventure.

Check the terminal connections periodically, as oxidation can build up even in dry climates. A thin application of dielectric grease on the terminals will prevent corrosion from moisture and salt spray. By keeping the connections clean and the charge levels steady, you ensure that the bike starts on the first attempt, regardless of how far from home the journey takes you.

Investing in a proper auxiliary battery setup is one of the most practical ways to turn a standard dual-sport into a capable, long-range touring machine. By choosing the right tray and installing it with attention to vibration and wiring integrity, you remove the biggest hurdle to extended backcountry travel. Get the hardware sorted, finalize the build, and start planning the next route; the trail is waiting.

Frequently Asked Questions (FAQs)

What is an auxiliary battery tray on a dual sport motorcycle?

An auxiliary battery tray is a rigid aftermarket bracket designed to hold a secondary battery securely on a dual sport motorcycle frame or subframe. This bracket prevents battery movement during hard off-road riding, protecting the casing from vibration cracks and chassis impacts. Most brackets bolt directly to existing luggage rack mounts or tuck under side fairings. Adding one allows riders to power auxiliary lighting, GPS navigators, and heated gear without draining the bike’s primary starter battery.

What does a dual battery setup do on a dual sport touring bike?

A dual battery setup isolates accessory power draw from your starting system so you do not drain the engine’s starter battery while touring. Dual sport stators often produce limited surplus power, typically between 50 and 150 watts above baseline engine needs. By routing camp lighting, tire inflators, and phone chargers to an auxiliary lithium pack, you ensure your motorcycle always has enough voltage to crank over in remote backcountry terrain.

How do I install an auxiliary battery tray on a dual sport motorcycle?

Installing an auxiliary battery tray involves bolting the bracket to reinforced subframe points and routing wiring through an ignition-switched relay or battery isolator. Begin by removing the seat and side panels to find a stable mounting area with clearance for rear wheel travel. Secure the tray using blue threadlocker on M6 or M8 stainless steel hardware to resist vibration. Finally, line the tray with high-density foam dampeners before strapping down a sealed AGM or lithium LiFePO4 battery.

How do you wire a secondary battery on a dual sport touring setup?

Wiring a secondary battery requires connecting it to your stator circuit using a smart battery isolator or voltage-sensitive relay. Run an insulated 10-gauge or 12-gauge positive wire from the main battery terminal through a 30-amp fuse to the isolator input. Connect the isolator output to the auxiliary battery positive terminal, and ground both batteries directly to the motorcycle frame or negative bus bar. This wiring charges both units while running but disconnects the secondary battery when the engine shuts off.

Aluminum vs steel auxiliary battery trays for dual sport touring: which is better?

Aluminum auxiliary battery trays are generally better for dual sport touring because they reduce rear subframe weight while providing adequate structural strength. A 5052 or 6061 aluminum tray typically weighs under 1.5 pounds, helping keep center-of-gravity low on technical singletrack. Steel trays offer higher impact resistance and are easier to weld-repair in third-world travel emergencies, but the extra weight can crack lightweight aluminum subframes over rough washboard roads.

How much does an auxiliary battery tray for dual sport touring cost?

Auxiliary battery trays for dual sport motorcycles usually cost between $45 and $160 depending on the material, mounting hardware, and bike fitment. Universal sheet-aluminum trays sit at the lower end around $45 to $75. Model-specific kits tailored for bikes like the Suzuki DR650 or Yamaha Tenere 700 often cost $110 to $160 because they include laser-cut brackets, stainless hardware, and molded retention straps. Expect to spend another $100 to $200 if you need a matching lithium battery.

What is the most common mistake when mounting an auxiliary battery tray?

Mounting the tray without checking rear suspension clearance is the most common and damaging mistake riders make during installation. If you position an auxiliary tray underneath the rear fender or luggage subframe, a fully compressed shock can slam the rear tire directly into the bracket. Always remove the rear shock spring or strap the suspension fully compressed to verify there is at least 1 inch of clearance before taking your loaded dual sport on technical trails.

Is an auxiliary battery tray worth the added weight for dual sport backcountry touring?

Adding an auxiliary battery tray is worth the weight if you run heated gear, recharge electronic navigation equipment, or travel through cold wilderness areas. When paired with a modern lithium iron phosphate (LiFePO4) battery, the entire tray and battery system adds less than 4 to 6 pounds total. That minimal penalty provides essential peace of mind against dead batteries in off-grid locations where push-starting a tall dual sport bike in sand or mud is nearly impossible.