How fragile is the radiator - Kawasaki KLR 650 Forum
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post #1 of 5 Old 04-21-2010, 04:30 PM Thread Starter
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Scott R Nelson's Avatar
Join Date: Aug 2009
Location: Folsom, CA
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How fragile is the radiator

Last Saturday quite a few KLR650's showed up for the dual sport ride that I organized, and it got me to wondering about the radiator.

One guy had to quit because he had dropped the bike and now the fan was in contact with the radiator. I noticed one other bike that had a home-brew radiator guard made from a piece of wood - a 2x2.

So how fragile is the radiator? How often do you guys have issues with it?

It's making me thankful for the ancient-technology air-cooled motor in my XR.

Scott R. Nelson, 2001 XR650L, and a KTM 990 Adventure, Folsom, CA
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post #2 of 5 Old 04-21-2010, 05:35 PM
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Location: Sacramento, CA
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Sounds like he bent the radiator. If it is not leaking it can POSSIBLY be straightened enough for use.

I know the Guards are expensive...

...but they are less expensive than a new radiator.


2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #3 of 5 Old 04-21-2010, 06:35 PM
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And it won't only be the rad. Could also add the fan and the plastic.

I'm thinking of getting the guards but supply seems to be a problem.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #4 of 5 Old 04-21-2010, 08:20 PM
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Radiators are not cheep I found them to start around 800.00 clams guards are cheep insurance. I built my own.

up grade's 2008 green,
Cee Baily tinted wind shield, studibaker skid plate, one inch length added to shifter, highway pegs, steel pegs,Jardine pipe, trunk, head light rock gard, , 12 volt power outlet, 16 tooth front sprocket, Progressive front springs, studibaker master cylender guard, PVC mod,Doo Hickey, one wheel offroad trailer, night vision ammo cans for side bags my oun tank gards.
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post #5 of 5 Old 06-10-2010, 10:00 PM
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Two weeks after I got my '02 I got hit by a car smack in the radiator. Busted the left front shroud off, and smooshed the radiator enought to think about replacing it. But after bending it back into a reasonable shape, it still functions well without any leaks. That's more than I can say for my shoulder. It all depends on how it gets damaged. I got lucky, two inches to the left, and the whole bike would be a mess! The bike actually got spinned 360 degrees, with a half twist. I hit the door post on the car with my left shoulder and did a complete flip, and landed about twenty feet behind the car, and my helmet never touched the ground or anything. Thank God.

So, there's more info than you asked for...sorry.

Oh yeah, the helmet was on my head at the time! LOL!

Last edited by sarthurk; 06-11-2010 at 06:56 PM. Reason: Duh.
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