Kawasaki KLR 650 Forum - View Single Post - Post photos of your homemade mods
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post #3 of Old 06-16-2013, 02:31 AM
2nd Gear
Join Date: Apr 2012
Location: Cairns, Australia.
Posts: 191
This is not really strictly a KLR thing as the fix was on my F650 Funduro BMW but it sure is in the KLR spirit!
I found the fan badly out of balance and a close inspection revealed a broken blade:

A quick check of the interwebby and I discovered I could get a new one, fan, motor, mount and shroud for a mere $245. But all I needed was that cheap plastic bit at the
front, and being a tightarse and a KLR owner I decided to fix it.
I had some thickish aluminium lying around:

But first I did a bit of balancing:

Now I had a template:

Yep, that looks okay.

A bit of shaping:

Some glue and rivets:

The finished product.

Works just fine.
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