[quote=planalp;97513]It's been a couple of years since I put mine on, but here's a pretty decent video of some guys installing the HT Nerf bar kit. As I recall, the instructions that came with the kit were somewhat lacking, or at least kind of unclear with poor, grainy black and white photos.
Biggest thing to watch is that the two flat support pieces that overlap and attach to the frame clamp, then pass out through the holes in the fairings, are correctly routed and installed and don't interfere with the voltage regulator or any other wires or hoses. Installing the whole bars/skid plate kit is a pretty easy job that doesn't take more than a couple of hours. I recall taking my front fender off to make the job easier but these guys didn't.
When I change my oil with the HT skid plate on, I stuff paper towels between the bottom of the engine case and the skid plate all around the skid plate oil drain plug access hole before I remove the drain plug. That way, when the flow of oil slows down, it won't creep out along the bottom of the engine case and get between the skid plate and the engine where you can't reach to wipe it out.
The HT highway pegs are steel covered with a thin piece of rubber. The first time you put your feet up on them, it will feel like you're resting your feet on an operating jackhammer. That sensation goes away the more you use them. I love mine. They save my back on longer rides.
+1 on seeing some photos of your KLR when you're done with all these additions.
I actually finished putting the set on a few days ago. It was pretty much as you describe. I think it took me around two hours.......the directions were ok, but not great. I'm glad it had the close-up pic of the voltage regulator or I probably would have placed the support on the wrong side of the wiring harness. The hardest part for me was getting the two frame bolts fed through both sides of the clamp and then into the two supports......for some reason I had a heck of a time getting the threads started.
I noticed the tolerance between the front supports and the plastic is very close.......so close in fact that I can barely slide a sheet of paper between the metal and the plastic on the right side. I'm a little concerned this could become an issue when rolling down the road. I thought about giving it a nudge with my boot, but the left side is sitting pretty close to the plastic itself??? Time will tell I guess.....