Wilsons Sandbox

Posted: **Tue Nov 23, 2004 5:07 pm**

--- In DSN_klr650@yahoogroups.com, "mbarney" wrote:

> The only fitment problem I had with the PD Nerfs was that the right > fork tube contacted them when steering was at full right lock. I > didn't like that, and had to bend the upper horizontal tube of the > right nerf to allow clearance. Quite a pain, but it clears now. > > -Matt

Hi Matt, Note:The only fitment problem I had with the PD Nerfs was that the right > fork tube contacted them when steering was at full right lock. I > didn't like that, and had to bend the upper horizontal tube of the right nerf to allow clearance. Quite a pain, but it clears now. BINGO @ fitment,unfortunately so. I love mine, BUT>>>> When I bought my new to me 2001 KLR, 2500miles last Nov, I also bought a set of used ebay nerfbars. After installation, I was puzzled why the bike made better turns to the left then the right.It was not until I had rode the bike over 3000miles that I commented on the difficulty I was having making Right hand turns when KLR/mechanic guru Jeff S. of South Dakota fame, said, "Look at this, the fork strikes the PD tube. I can fix that." We (I watched) chopped off (YIKES) the end and he welded it 180 degrees from its previous orientation (OCC calls the chop and weld, chop again if necessary, fabrication.) Previously, the orientation was top-tube forward of the bolt hole, corrected, it was tube trailing the mounting point. Jeff sent Happy trails an email, that "we experienced this problem, appears the jig is backwards, you might want to look at this, this is what we did to fix the problem," (without any compensation,etc), friendly email etal, FYI, could you look at this, etc. NO REPLY from happy trails. Yeah they are busy, but not to busy to take your money if you want to buy something.... This email of Matt's confirms something is not right with the HT PD nerf bar construction technique. Saying all this, I love my bars. I bought the bars because I knew I was going to fall down, I did, I have, I will, and front loaded the cost of PD bars as a preventative measure, it worked. Regarded as overkill by some, true, but if you don't fall down, you probably are riding very near the edge of the envelope. My envelope is much larger now than it was a year ago, and I have yet to replace anything that I "over-protected." And not one regret for doing so... I also bought the brake billet, reservoir cover and the aluminum shark fin for the bake brake disc, skid pan, mirror dampners, aluminum hand guards, and more, all of which have paid for themselves all ready in the form of parts I did not replace, while they were protecting the bike from me! Needless to say, the bike now turns equally easy left and right, and did I feel a little foolish at the time. I knew something was not quite right, nor would the fork lock to the right, had a huge, I mean really huge turning radius to the left. Mostly not recognizing the problem is related to to the phenomena I call "lack-of -recent experience" with MC's (last bike was an R50/5 in 1976.) The lack of recent experience is almost cured and I got a great bike with the professional help of Jeff S. and the cheering squad at http://autos.groups.yahoo.com/group/DSN_klr650 ! Thanks to you all. If you think somenting is not right. Ask. and read the FAQ's. Checking Millerized Pookie's installation instructions, it also showed the right side being bolted up in a trailing position. Millerized: does your fork strike the PD nerf bar? Any others out there have the fork tubes strike the PD tubes? Enquiring minds want to know. And thanks Matt, for posting the comment about the steering head striking the right horizontal brace. I should have posted it earlier, but thought it was an anomaly, obviously, it was't. Which makes the PD NERF Bar manufacturing snafu even more irratating. (Yes the forks are/were straight in the steering head, etal.) And what did we learn in all of this...well, most of all, this help (with a bunch more mods/improvements to follow, to include a Great Divide Ride) from my friend Jeff S. all came from an introduction on the KLR list. Thanks to all who constructivly add to the wit and wisdom of the KLR list. It is the best cult I have ever been in (;~). revmaaatin. Martin Earl mjearl@... 605-852-2424

Posted: **Tue Nov 23, 2004 7:03 pm**

I bought the Happy Trails Radiator/Reservoir Guard from Arrowhead and have the same problem for both left and right turns. Both fork tubes strike the guard tubing and prevent full turns as well as locking the forks. As you commented, both have the tubing about 45 degrees forward of the mount hole. I reversed the mount and the upper clears, but the lower holes do not line up with the radiator/reservoir. I sent an email to both Fred and Happy Trails about it. I received a reply from Fred about another subject, (13t sprocket), but nothing about the guard. I got no reply at all from Happy Trails. I only do off-roading with the KLR, so I've left them on for now. After reading your statement, I'll find someone with a welder and have them rotate the ends 90 degrees so they angle forward. I have 3/4" clearance between the tubing and the Rad/Res factory guards. Greg McKinney '95 A9 -----Original Message----- From: revmaaatin [mailto:mjearl@...] Sent: Tuesday, November 23, 2004 5:07 PM To: DSN_klr650@yahoogroups.com Subject: [DSN_klr650] PD NErf Bar fitment

--- In DSN_klr650@yahoogroups.com, "mbarney" wrote: > The only fitment problem I had with the PD Nerfs was that the right > fork tube contacted them when steering was at full right lock. I > didn't like that, and had to bend the upper horizontal tube of the > right nerf to allow clearance. Quite a pain, but it clears now. > > -Matt Hi Matt, Note:The only fitment problem I had with the PD Nerfs was that the right > fork tube contacted them when steering was at full right lock. I > didn't like that, and had to bend the upper horizontal tube of the right nerf to allow clearance. Quite a pain, but it clears now. BINGO @ fitment,unfortunately so. I love mine, BUT>>>> When I bought my new to me 2001 KLR, 2500miles last Nov, I also bought a set of used ebay nerfbars. After installation, I was puzzled why the bike made better turns to the left then the right.It was not until I had rode the bike over 3000miles that I commented on the difficulty I was having making Right hand turns when KLR/mechanic guru Jeff S. of South Dakota fame, said, "Look at this, the fork strikes the PD tube. I can fix that." We (I watched) chopped off (YIKES) the end and he welded it 180 degrees from its previous orientation (OCC calls the chop and weld, chop again if necessary, fabrication.) Previously, the orientation was top-tube forward of the bolt hole, corrected, it was tube trailing the mounting point. Jeff sent Happy trails an email, that "we experienced this problem, appears the jig is backwards, you might want to look at this, this is what we did to fix the problem," (without any compensation,etc), friendly email etal, FYI, could you look at this, etc. NO REPLY from happy trails. Yeah they are busy, but not to busy to take your money if you want to buy something.... This email of Matt's confirms something is not right with the HT PD nerf bar construction technique. Saying all this, I love my bars. I bought the bars because I knew I was going to fall down, I did, I have, I will, and front loaded the cost of PD bars as a preventative measure, it worked. Regarded as overkill by some, true, but if you don't fall down, you probably are riding very near the edge of the envelope. My envelope is much larger now than it was a year ago, and I have yet to replace anything that I "over-protected." And not one regret for doing so... I also bought the brake billet, reservoir cover and the aluminum shark fin for the bake brake disc, skid pan, mirror dampners, aluminum hand guards, and more, all of which have paid for themselves all ready in the form of parts I did not replace, while they were protecting the bike from me! Needless to say, the bike now turns equally easy left and right, and did I feel a little foolish at the time. I knew something was not quite right, nor would the fork lock to the right, had a huge, I mean really huge turning radius to the left. Mostly not recognizing the problem is related to to the phenomena I call "lack-of -recent experience" with MC's (last bike was an R50/5 in 1976.) The lack of recent experience is almost cured and I got a great bike with the professional help of Jeff S. and the cheering squad at http://autos.groups.yahoo.com/group/DSN_klr650 ! Thanks to you all. If you think somenting is not right. Ask. and read the FAQ's. Checking Millerized Pookie's installation instructions, it also showed the right side being bolted up in a trailing position. Millerized: does your fork strike the PD nerf bar? Any others out there have the fork tubes strike the PD tubes? Enquiring minds want to know. And thanks Matt, for posting the comment about the steering head striking the right horizontal brace. I should have posted it earlier, but thought it was an anomaly, obviously, it was't. Which makes the PD NERF Bar manufacturing snafu even more irratating. (Yes the forks are/were straight in the steering head, etal.) And what did we learn in all of this...well, most of all, this help (with a bunch more mods/improvements to follow, to include a Great Divide Ride) from my friend Jeff S. all came from an introduction on the KLR list. Thanks to all who constructivly add to the wit and wisdom of the KLR list. It is the best cult I have ever been in (;~). revmaaatin. Martin Earl mjearl@... 605-852-2424 List sponsored by Dual Sport News at www.dualsportnews.com List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html Yahoo! Groups Links

Posted: **Tue Nov 23, 2004 9:43 pm**

I bought my PD Nerf Bars early in 2004 and after installation the fork touched the right nerf bar before it hit the lock. Not by much. Maybe a sixteenth to an eigth of an inch. I posted that fact on this board since I assumed that I had done something incorrectly. I bent the nerf enough so that it's now pretty close. Certainly not enough to effect a turning radius, but still, not what I had hoped in terms of fitment. Still, I like my bars very much, and would buy them again. Randy

Posted: **Tue Nov 23, 2004 9:48 pm**

Know of one KLR that had a marked differance in bar lock. On inspection the stop tabs on the frame were of differnt length. Some welding to raise the shorter one worked out fine. Zac -----Original Message----- From: Randy Shultz [mailto:rshultz@...] Sent: Tuesday, November 23, 2004 7:44 PM To: DSN_klr650@yahoogroups.com Subject: [DSN_klr650] Re: PD NErf Bar fitment I bought my PD Nerf Bars early in 2004 and after installation the fork touched the right nerf bar before it hit the lock. Not by much. Maybe a sixteenth to an eigth of an inch. I posted that fact on this board since I assumed that I had done something incorrectly. I bent the nerf enough so that it's now pretty close. Certainly not enough to effect a turning radius, but still, not what I had hoped in terms of fitment. Still, I like my bars very much, and would buy them again. Randy List sponsored by Dual Sport News at www.dualsportnews.com List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html Yahoo! Groups Links

Posted: **Wed Nov 24, 2004 9:07 am**

--- In DSN_klr650@yahoogroups.com, "Ramey" wrote:

> Know of one KLR that had a marked differance in bar lock. On

inspection the

> stop tabs on the frame were of differnt length. Some welding to

raise the

> shorter one worked out fine. > > Zac >

I will check that out. It's very possible that the problem with my fitment is with variances in my KLR, not with the PD Nerf Bars. As I said, I am very happy with my PD Nerf Bars, and would gladly purchase them again. It was the fitment of the two together that I was a slightly disappointed with, and the problem could very well be with my 2004 KLR and not the bars. I just mentioned it because someone noted their forks hit the bars before the stops and asked if anyone else had the same issue. Randy

Posted: **Wed Nov 24, 2004 11:10 am**

--- In DSN_klr650@yahoogroups.com, "revmaaatin" wrote:

> > If you think somenting is not right. Ask. and read the FAQ's. > Checking Millerized Pookie's installation instructions, it also > showed the right side being bolted up in a trailing position. > Millerized: does your fork strike the PD nerf bar?

It did, and I think it was something like 1/8" or less of interference. If you needed that last 1/8" or so when riding, well, it's not going to make that big a difference cause you're only ever going to use it at low speed. Turning lock to lock at anything other than walking speed is going to get some use out of those PD's. I ignored mine until the first get-off. Then it indexed itself, and no problems since. If it's that big a concern, whack it with a rubber mallet (it's just soft tube steel, not titanium) and clearance it. Having 1 bike to work with doesn't necessarily make it fit on all bikes. There may be a bit of adjustment needed. First time you need them, it'll adjust itself. Promise! millerized

Posted: **Wed Nov 24, 2004 5:10 pm**

I don't have the nerf bars but a friend of mine does and when he was over today I checked his bike (A-17) and sure enough his fork tube hit the bars when turned far right, which was news to him. It did not hit by much and to check any decrease in turning radius we used a chalk line along the tire at straight, hard right and hard left. Quess what the angle was in fact reduced but on the hard left. The hard right which contacted the fork tube and nerf bar actually has a sharper (more acute) turning angle. Upon further investigation it was determined the welded bar stop behind the stem was, in KHI style, welded with the precision of a mildly intoxicated gibbon resulting in more travel to the extream right than left. I belive someone else mentioned this as well but this extra travel to the right was the reason for the contact and would account for fitment problems among bikes. --Jim A-15

> It did, and I think it was something like 1/8" or less of > interference. If you needed that last 1/8" or so when riding, well, > it's not going to make that big a difference cause you're only ever > going to use it at low speed. > If it's that big a concern, whack it with a rubber mallet (it's just > soft tube steel, not titanium) and clearance it. Having 1 bike to > work with doesn't necessarily make it fit on all bikes. There may > be a bit of adjustment needed. First time you need them, it'll > adjust itself. Promise! > millerized

Posted: **Wed Nov 24, 2004 7:00 pm**

I contacted Happy Trails about this fitting problem and they expressed to me that they thought it was the fit and finish of the KLR that was the problem. Fred http://www.arrowheadmotorsports.com http://www.angelfire.com/ut/moab/cmc.html

----- Original Message ----- From: "Randy Shultz" To: DSN_klr650@yahoogroups.com> Sent: Wednesday, November 24, 2004 8:05 AM Subject: [DSN_klr650] Re: PD NErf Bar fitment > > > --- In DSN_klr650@yahoogroups.com, "Ramey" wrote: > > Know of one KLR that had a marked differance in bar lock. On > inspection the > > stop tabs on the frame were of differnt length. Some welding to > raise the > > shorter one worked out fine. > > > > Zac > > > > I will check that out. It's very possible that the problem with my > fitment is with variances in my KLR, not with the PD Nerf Bars. As I > said, I am very happy with my PD Nerf Bars, and would gladly purchase > them again. It was the fitment of the two together that I was a > slightly disappointed with, and the problem could very well be with > my 2004 KLR and not the bars. > > I just mentioned it because someone noted their forks hit the bars > before the stops and asked if anyone else had the same issue. > > Randy

Posted: **Wed Nov 24, 2004 8:33 pm**

So the after market part don't fit, so the factory should change the bike? Something don't sound right. Joe SE Ky A18

--- In DSN_klr650@yahoogroups.com, "Fred Hink" wrote: > I contacted Happy Trails about this fitting problem and they expressed to me > that they thought it was the fit and finish of the KLR that was the problem. > > Fred > http://www.arrowheadmotorsports.com > http://www.angelfire.com/ut/moab/cmc.html > > > > > ----- Original Message ----- > From: "Randy Shultz" > To: DSN_klr650@yahoogroups.com> > Sent: Wednesday, November 24, 2004 8:05 AM > Subject: [DSN_klr650] Re: PD NErf Bar fitment > > > > > > > > --- In DSN_klr650@yahoogroups.com, "Ramey" wrote: > > > Know of one KLR that had a marked differance in bar lock. On > > inspection the > > > stop tabs on the frame were of differnt length. Some welding to > > raise the > > > shorter one worked out fine. > > > > > > Zac > > > > > > > I will check that out. It's very possible that the problem with my > > fitment is with variances in my KLR, not with the PD Nerf Bars. As I > > said, I am very happy with my PD Nerf Bars, and would gladly purchase > > them again. It was the fitment of the two together that I was a > > slightly disappointed with, and the problem could very well be with > > my 2004 KLR and not the bars. > > > > I just mentioned it because someone noted their forks hit the bars > > before the stops and asked if anyone else had the same issue. > > > > Randy

Posted: **Wed Nov 24, 2004 9:40 pm**

Rather than bitch to the list why don't you contact the manufacturer. Contact Tim at Happy Trails at: tim.bernard@... I have already expressed my opinions. Fred If the glove don't fit you must acquit.

----- Original Message ----- From: "Joseph Jones" To: DSN_klr650@yahoogroups.com> Sent: Wednesday, November 24, 2004 7:32 PM Subject: [DSN_klr650] Re: PD NErf Bar fitment > > > > So the after market part don't fit, so the factory should change the > bike? > Something don't sound right. > Joe SE Ky A18 > > > --- In DSN_klr650@yahoogroups.com, "Fred Hink" wrote: > > I contacted Happy Trails about this fitting problem and they > expressed to me > > that they thought it was the fit and finish of the KLR that was the > problem. > > > > Fred > > http://www.arrowheadmotorsports.com > > http://www.angelfire.com/ut/moab/cmc.html

Wilsons Sandbox

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