Crash Bars are a Must
You must have crash bars because you have to get used to putting your bike down occasionally and not worrying about it. I'm not hard-core and don't anticipate really tearing up my bike, but even those low-speed "excuse me" tip-overs can tear up all the fragile plastic parts on a KLR and you'll soon spend as much as if you had just put on the crash bars on in the first place. The stock plastic skid plate is really not too bad for basic use - I unintentionally made some pretty good use of it going over some trees. But as a practical matter you need a bigger, stronger metal skid plate and the stock one is not compatible with many of the crash bar setups. So an upgrade is in order.
You must have crash bars because you have to get used to putting your bike down occasionally and not worrying about it. I'm not hard-core and don't anticipate really tearing up my bike, but even those low-speed "excuse me" tip-overs can tear up all the fragile plastic parts on a KLR and you'll soon spend as much as if you had just put on the crash bars on in the first place. The stock plastic skid plate is really not too bad for basic use - I unintentionally made some pretty good use of it going over some trees. But as a practical matter you need a bigger, stronger metal skid plate and the stock one is not compatible with many of the crash bar setups. So an upgrade is in order.
Happy Trails PD Nerf Plus Skid Plate
The Happy Trails PD Nerf and Skid Plate Combo (PD for Paris to Dakar) is a sturdy, well designed combination crash bars + skid plate with the added bonus of foot pegs to rest your feet on those long rides. Installation is well within the average person's ability. Be prepared to disassemble much of the plastic and fairings on the front of the bike and set aside a long afternoon. I'd also recommend you also get Allen wrench socket ends of 5 & 6 mm, plus Torx T-40 to go on your standard 3/8" socket wrench set - you'll be much happier.
The instructions provided are very good, and HT has a support website with more pictures and instructions. There is also a nice Youtube video showing a full installation that you should watch a couple times before starting.
I found the HT products to be manufactured to very accurate dimensions and you can expect it to fit perfectly. T hat said, on the KLR this product is a tight fit and there's a fair amount of careful finagling to get everything in the correct position. From experience, I can tell you that if you're installing things correctly, you can expect the pieces line up perfectly. If they're not lining up, its more likely you're the problem.
The instructions provided are very good, and HT has a support website with more pictures and instructions. There is also a nice Youtube video showing a full installation that you should watch a couple times before starting.
I found the HT products to be manufactured to very accurate dimensions and you can expect it to fit perfectly. T hat said, on the KLR this product is a tight fit and there's a fair amount of careful finagling to get everything in the correct position. From experience, I can tell you that if you're installing things correctly, you can expect the pieces line up perfectly. If they're not lining up, its more likely you're the problem.
After installing, all the pieces tightened up in alignment and and the HT bars fit around all of the KLR plastic perfectly. The bars are rock solid and cross-braced and will definitely protect the machine. Should you damage one of the foldable foot pegs, they are easily replaceable from HT.
An Unsolicited Endorsement for Happy Trails Product Support
In spite of the excellent instructions, photos and videos, there are still ways for you to have something out of position and stuff just doesn't line up! Before you get frustrated, call or email HT support and they are very responsive, friendly, and knowledgeable. I made a simple mistake myself and wasted a couple hours before a 5 minute call got me back on track.
Summary
The Happy Trails PD Nerf and Skid Plate combo is highly recommended. The HT people not only build good stuff but they stand by what they manufacture and help you after the sale.
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