After years of requests from our KLR side rack customers, Precision Motorcycle Racks has designed an upgraded rear rack insert to replace the stock plastic one. For the last few months, we have been getting the design and materials right while adding Rotopax/Wolfman/DrySpec/Rok Straps product compatibility, and an optional sissy bar attachment (6 and 8 inch). They are now available ($85) for the 1987-2007 and 2008-present KLR's on www.pmracks.com Amazon and Ebay. https://www.pmracks.com/products.php?id=157 https://www.pmracks.com/products.php?id=158 Here is a quick rundown on the design process if you are interested:



The first one of these we saw, the SW Motech version, was brought to our attention by a customer who liked it but didn't want to spend the $115-125. We loved the idea of replacing the stock plastic insert in favor of something better looking with a lot more tie down points, at a realistic KLR rider price point. Once we looked into it, we realized SW Motech had failed in a couple areas on this one, and almost no one we saw online or in SoCal/Baja area had one of these despite being a pretty cool upgrade (due to the high price and the fact it actually added weight due to it being made from 1/8 inch steel). Our first attempt at the insert was also made from 1/8 inch steel (due to projected low cost and high strength), but even after adding 16 cutouts it was just too heavy. In order to get it light enough to match the stock insert's weight, we had to remove too much surface area, which took away from the strength and left large gaps in the platform surface. Next, we made a small run of 1/8 inch aluminum ones. They were plenty light enough but too flexible for long term off road use. Also, because we wanted to countersink the mounting holes, the 1/8 inch was cutting it too close for the bolt head to bite at full strength due to aluminum being so much softer than steel. We ended up going with 3/16 inch aluminum and it worked and felt great. Even though it cost 50% more for the material and ran 50% slower on the CNC laser, the 3/16 was the way to go. It beat the stock insert in weight and strength, and it had the right overall feel for an off road environment. With the addition of machined aluminum spacers, stainless countersunk hardware, Rotopax/Wolfman/DrySpec/Rok Straps product compatibility, optional sissy bar attachment, and a lifetime warranty for $85, we hope this becomes a standard upgrade in the next few years for the KLR community. We welcome your feedback. Ride safe - PMR Team