Now I want to buy crash bars, but these nerf bars look a little bit flimsy for the weight of the KLR. Does anyone have experience with these? Any field testing/crash testing?
I think it'd be cool to get the skid plate, highway footpegs/engine guard, nerf/crash bars, and a cupholder for around 300 bucks. I just worry about a crash. My radiator is already bent, and dropping 300 on a new radiator is less fun than crash bars. What I really don't want to do is put down 300 on nerf bars that arn't sufficient, only to drop it and find that the nerf bars were inadequate and my radiator busts.
I've HT PD nerfs, engine guard, highway pegs, bash plate on my '07.
YES, I've crash-tested 'em. The assemblage has protected my radiator, tank, and plastics, the purpose of the augmentation.
The PRIMARY purpose is trail survival, in my case--you can limp home with cracked plastic, but . . . NOT a broken radiator or crankcase.
Now, "flimsy?" If you're after unbendable/unbreakable, go somewhere else. The nerfs, etc., are in a way SACRIFICIAL parts in my view, offered up in lieu of a radiator, lets say. Most usually, the parts can be bent back into neo-decent shape, or . . . Happy Trails offers price consideration for purchase of replacement/repair parts.
A bent nerf beats a broken radiator, in my book. Highway pegs? Seldom use 'em; don't like to give up vigilance and control; YMMV.
Excellent customer service from Happy Trails; instruction sheet competence? Not so much! But, you can figure it out.
One installation tip: On Generation 1 nerfs, insert the left upper nerf bolt through the frame on the RIGHT side; that way, you have only one 10 mm nut to remove to free the left nerf for folding it away to reach the radiator cap.