We are constantly testing our products to ensure the highest design quality is passed to our valued customers. With this in mind we have released a second generation improved crossover design (a key component to our PD Nerf setup) for the '08 > KLR650. We're making this update available at our cost plus shipping. Please read details and order below:
Every kit since June 15 2008 has this update. If you have crashed your bike this is the replacement kit you need to order
On the 2008 > KLR650 PD Nerf bar setup, the crossovers are the two flat pieces of metal that mount to the center down tube on the bike behind the radiator (left) reservoir (right) and serve to connect the left and right sides of the PD Nerf bars. In the attached image the crossovers are the two horizontal flat pieces that connect together in the center (closest to the camera).
In our initial production run the crossovers were not as strong as they could be. This upgraded crossover is made from .250 inch thick aluminum versus the original .125 inch thick steel parts. You can measure the thickness of your crossover to verify that you have the upgraded parts. Please note: all PD Nerf orders after June 15, 2008 include the newer crossover design.
The instructions don't show whether the Right crossbar goes in front of or behind the coolant tank outer support. If I put it between the support and the coolant tank, the fairing won't fit back on. If I put it behind the support, the crossbar puts pressure on the regulator wiring.
There are a set of detailed instructions located here
It is the 15th picture down that address this.
Does this come with longer bolts?
The kit comes with new 6mm bolts and rubber washers for the outside. The original kit bolts for the clamp are not replaced.