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I bought a 2016 KLR love love love it but unfortunately I got my ass kicked on a muddy trail and my bike is now in the shop with a broken/bent rad and a seized rad fan. I got a price of a new rad from Kawasaki and it was approx 750$ CAD! I couldn't believe it did anyone else have an issue similar to this and what did you do? I work in refrigeration and some of the coils (rads) we install don't cost as much as this so I'm just looking for some insight. Also when the bike gets repaired will there be any loss of performance from this?

Thanks
Bryce
 

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That's one of the reasons I installed crash guards immediately. I've heard the rad is $800 bucks not to mention the cowling and other stuff. Apparently if u drop it on left side, there is a good chance of having to replace the radiator. I can barely get the balls of my feet to touch so I didn't want to risk it. I would def suggest adding good crash guards. They will pay for themselves over time.
 

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+ 1 on the crash guards ("nerfs"), an IMS plastic tank offers similar protection, plus increased fuel supply.

I consider some radiator/engine/tank/control levers essential for trail survival.

The World's Greatest Motorcycle Radiator Repair Facility can likely fix the radiator (think they're in Utah of someplace, "Myler's?"), but the international back-and-forth may cost as much as a new radiator. Some have opted for low-budget Chinese radiators; good luck!
 

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I'm getting my rad looked at by
A rad guy but worst case scenario is I'll probably buy a new rad for it from Kawasaki I'm not confident enough to put one of the cheap Chinese 80$ ones in I imagine you get what you pay for, this all shouldn't effect the performance or life span of the bike right?
 

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I bought a 2016 KLR love love love it but unfortunately I got my ass kicked on a muddy trail and my bike is now in the shop with a broken/bent rad and a seized rad fan. I got a price of a new rad from Kawasaki and it was approx 750$ CAD! I couldn't believe it did anyone else have an issue similar to this and what did you do? I work in refrigeration and some of the coils (rads) we install don't cost as much as this so I'm just looking for some insight. Also when the bike gets repaired will there be any loss of performance from this?

Thanks
Bryce
Same conundrum last spring on my '15. Tweaked my radiator after a dumb wheelie, Sent it to MYLER'S RADIATORS in utah, seems like if it's fixable they're the ones to fix it. I think it was like $70.
 

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1) now you know why guys buy IMS tanks or crash bars.

2) Do NOT buy the cheapy e-bay rads; get yours fixed or replace it with a Myler's supercool unit. It's the only one that actually fits and works better than stock. www.rockymountainatvmc.com/p/1435/34041/Mylers-Aluminum-Radiator

3) If your fan is actually pooched, the EX500 one is said to work and is much cheaper.

4) these are also a good idea although a bit superfluous with crash bars; 2008-2016 KLR650 Radiator Guard - JNS Engineering



Hope this helps,
Dave
 

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I'm getting my rad looked at by
A rad guy but worst case scenario is I'll probably buy a new rad for it from Kawasaki I'm not confident enough to put one of the cheap Chinese 80$ ones in I imagine you get what you pay for, this all shouldn't effect the performance or life span of the bike right?
Firstly welcome to the Forum. It would benefit everyone if you would include your loaction information in your Profile. Where are you located? Are there any options for used parts in your area? Around Edmonton there are a couple of wreckers they may have a good rad. To my knowledge the rad is the same in all KLR years.

The performance or life span of the bike should not be affected - unless there's something that you are not telling us - like that you overheated the bike in the process.
 

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Firstly welcome to the Forum. It would benefit everyone if you would include your loaction information in your Profile. Where are you located? Are there any options for used parts in your area? Around Edmonton there are a couple of wreckers they may have a good rad. To my knowledge the rad is the same in all KLR years.

The performance or life span of the bike should not be affected - unless there's something that you are not telling us - like that you overheated the bike in the process.
Sorry klr4evr,
There are 2 different Gen 2 radiators. And 2 different Gen 2 fan assemblies.

This is another reason to love the OLD Gen 1 bikes. Most years parts fit all, in more instances.
 

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I was buying handguards from RockyMtn recently and noticed some Tusk radiators for the KLR. IIRC, $90 for a new aluminum one. Anyone have exp with these? Seems affordable enough to hang up a spare for the just in case.
 

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Sorry klr4evr,
There are 2 different Gen 2 radiators. And 2 different Gen 2 fan assemblies.

This is another reason to love the OLD Gen 1 bikes. Most years parts fit all, in more instances.
That's why I said - "to my knowledge" - it's limited.

So details on the differences would be helpful and the affected years. Assuming then that one doesn't fit the other?
 

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I was buying handguards from RockyMtn recently and noticed some Tusk radiators for the KLR. IIRC, $90 for a new aluminum one. Anyone have exp with these? Seems affordable enough to hang up a spare for the just in case.
I noticed those too. These are made in China units similar to the offerings on eBay. You take your chances with the quality and durability. They have a good rating from the people who bought them but just because they fit and hold water doesn't mean they will perform well in the long run. I'd want to hear from some one whose has had one installed for a few years.
 
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Don't do it man! You get what u pay for. I bought a set of knockoff shorty levers for my cb1000r and they showed up 2 completely different color shades. After going back and forth with the company for weeks, I finally got a new set. I mounted them and they wouldn't work on half of the adjustments on the clutch side. And they weren't even usable with the slack they had imo. After that, I can't imagine trusting a knockoff radiator to keep the heart of my bike running. That's just me. My thought process was the same. A good set of levers was 250 or so, I figured how could I go wrong with 40 bucks. Well after one ride, I realized my 40 bucks was gonna sit in a draw until I threw them out.
 

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I can't see paying serious money for such a poorly designed product. I would use it as an opportunity to reengineer it.
 

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The Tusk handguards I ordered were marked as made in Thailand. They appear well buildand hae a good reputation for all of theirproducts. Hell, I believe my KLR was made in Thailand, too.

As time goes by I am finding myself less and less worried about a parts Country of origin, and more concerned with how it performs. The Motion Pro lever that just replaced my stock Kawi piece fit MUCH better than stock and has a bushed pivot that the OEM piece lacked. They are from Taiwan.

Cheap parts concern me, but Asian countries don't. lol

Mylers repairs radiators at home, but I highly doubt they build the new ones they sell from scratch. Anyone know where he buys his units from? Just saying...if he's getting $300 for a $99 Chinese radiator I'd have to laugh...and pat him on the back.
 

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So details on the differences would be helpful and the affected years. Assuming then that one doesn't fit the other?
As Damocles showed us, we have discussed this before. But here is a quick over-view.

Gen 1, 1987-2007 radiators are interchangeable.
Gen 2 radiators changed starting 2015.

Basically the 2008-2014 radiators had 2 fan Mounts on the LH side and one at top RH.

The 2015 and Up radiators have 2 fan Mounts on the Inner RH side and one at the top LH.

One must have the proper fan bracket for the proper radiator.
 

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In the field radiator repair

Just an FYI. I repaired a leak on the radiator on a '65 Mustang about 10 years ago with JB Weld (Kwik-5 minute), and it's still going strong with no leaks. I carry some with me on my KLR all the time.
 
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