Leaving off radiator shrouds? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 7 Old 10-27-2017, 08:07 PM Thread Starter
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Leaving off radiator shrouds?

Hi, I'm a new motorcycle rider and I just bought a 2003 klr 650. The radiator shrouds were fairly broken (it was obviously dropped a lot) and held on via zip ties, which makes removing the tank annoying, so I decided to just leave them off for now. Do you think this will cause any real harm? I plan to use the bike almost exclusively for street riding, at least for now.
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post #2 of 7 Old 10-27-2017, 10:01 PM
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No harm done. Just looks funky. May run a smidgeon warmer in the summer time, but that is OK.
If the gauge is not 7/8th to the HOT Zone, its not too hot!
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pdwestman
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Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 7 Old 10-27-2017, 10:43 PM
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Agree completely with pdwestern on the function and what to watch out for.

You might take what's left of the old shrouds and trim them back to just about an inch or inch and a half wide. Trim off all but just enough to cover the leading edge of the gas tank. Then use a bit of RTV Sealant to glue them onto the gas tank. The RTV Sealant is easily removed later, if you or some future owner should decide differently. But if the trimming is done with a bit of care, it might look like a factory conversion unless viewed really up close and personal. Just my 0.02.
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post #4 of 7 Old 10-28-2017, 12:48 PM
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No, no problem functionally and, in fact, Bill tested the Gen1 without shrouds and found a small benefit IIRC. .....yes it's ugly without them.

Another option; IMS 6.6 gallon tank; no shrouds, no rust, no dents, no need for crash bars, carries the weight a bit lower and no gas cap vent issues......swap the petcock for a raptor manual at the same time and you've eliminated a bunch of potential common KLR issues.

Dave
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post #5 of 7 Old 10-28-2017, 12:49 PM
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post #6 of 7 Old 03-18-2019, 03:57 PM
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Quote:
Another option; IMS 6.6 gallon tank; no shrouds, no rust, no dents, no need for crash bars, carries the weight a bit lower and no gas cap vent issues......swap the petcock for a raptor manual at the same time and you've eliminated a bunch of potential common KLR issues.
Does that gas tank really provide protection akin to using crash bars? I'm considering buying an 06 that's missing both gas tank fairings and will be riding in South American where the extra fuel capacity will be useful Ė so this seems like a great fix for me, but it just seems too good to be true.
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post #7 of 7 Old 03-18-2019, 04:24 PM
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Quote:
Originally Posted by explorak View Post
Does that gas tank really provide protection akin to using crash bars? I'm considering buying an 06 that's missing both gas tank fairings and will be riding in South American where the extra fuel capacity will be useful Ė so this seems like a great fix for me, but it just seems too good to be true.
Akin? yes.....as good? that would depend on the specific crash. What I can tell you is that I've crashed hundreds of times on bikes with plastic fuel tanks (OEM, IMS and Clark) and haven't had a single issue. I've crashed the KLR maybe a dozen times offroad with the IMS tank with no damage.

I do suggest replacing the weak factory screen in front of the rad with the JNS rad guard as it's a stout pce that adds strength to the whole assy IMO.

A quality crash bar may add even more crash resistance which could be a consideration for a long trip away from any support, but for me, the extra weight is too much of a negative for any marginal improvement in protection.



2 cents,
Dave
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