Radiator woes

[Kwikasfuki]

Here's pic of the clearance and the point at which the damage occurs

[O.C.]

now that looks pretty close to me... and maybe doesn't allow much for any 'flex' 

[Martin#30]

That second picture looks like it is the fan housing rather than the fan blades hitting the rad. As OC says, there is not much clearance there, but as the fan is rigidly mounted to the radiator, the whole rad/fan assembly should move together. Odd. 

I wonder if the rest of us are likely to get the same issue over time.

Martin.

[Kwikasfuki]

That second picture looks like it is the fan housing rather than the fan blades hitting the rad. As OC says, there is not much clearance there, but as the fan is rigidly mounted to the radiator, the whole rad/fan assembly should move together. Odd. 

I wonder if the rest of us are likely to get the same issue over time.

Martin.

I hope mine was a one off and not a common issue.

Although the assembly looks rigid, any slight pressure to the rear of the fan results in quite a bit of flex. I may remount with some spacers (once I've checked nothing is forcing the fan assembly forward)

[Andy]

Currently radiator is completely off the bike so it can get fixed. I just want to make sure I have the refill sequence correct:

1. Attach hoses back to radiator. Is there anything special I need to do here like cleaning the connection points?
2. Fill radiator with anti-freeze by removing radiator cap. Note, this the cap on the radiator and not the reserve tank on the left fairing.
3. Fill the overflow bottle to the correct fill level
4. Start engine and monitor for leaks
5. Let engine cool and refill radiator and reserve tank

Does the above sound correct?

6. Fit radiator guard :-)

[Kwikasfuki]

6. Fit radiator guard :-)

Can't fit one on the rear, where the issue was!

[Boomer]

If the gouge is where the frame is then I'd say that looks like it was damaged before the bike was built.
Chances are someone dropped it and then just fitted it without checking for damage.
Either that or else it got damaged during the last major service.

If the gouge is where the blades pass by then you could possibly have had something caught in the fan blades.

Bummer, but at least ya got it fixed. 

[Kwikasfuki]

It's come back with massive weld on the back. The fan defo needs to be raised now.

[Kwikasfuki]

Its ready to be put on. I cleared out some of the gunk between the fins (I used it as emergency repair) and then got another pressure test done to ensure there were no further leaks.

I thought the left fan was close to the radiator. The right fan is almost touching it. I can see some scouring on the radiator on the right hand side which is definitely from the fan. Will be putting spacers onto prevent that.

Will also change the thermostat at the same time

[Kwikasfuki]

Couldn't be arsed changing the thermostat in the end 

Bike is back together and the fairing was a bitch to put back for some reason. Both fans now have spacers and heating/cooling seems to be fine.

Time to take it for a spin for an hour or so just to make sure nothing is amiss.

[frenchbiker]

Kawa fans are crap, both plastic, one large and one smaller. I changed them right after i got the bike. Aluminium metal grade from Muzzy, blades do not move and bike cooling is better. I had no choice when i was riding in Asia...
www.muzzys.com

[Kwikasfuki]

The fans about about 5mm higher and the spin at full load seems to be fine.

I also put on a radiator guard. I've noticed the bike runs a notch hotter now. I may get those fans from muzzy's and put them on.

Falling back in love with my bike and rethinking about getting a new model

[Lonewolf]

Glad its all back together. If its working fine and there's no dramas you might as well keep it.

[shaggs147]

You shouldn't have any issues with the repair, but for peace of mind, a little radweld in the system as a backup in case it "pin holes" wouldn't go amiss. Glad its sorted.

[frenchbiker]

The fans about about 5mm higher and the spin at full load seems to be fine.

I also put on a radiator guard. I've noticed the bike runs a notch hotter now. I may get those fans from muzzy's and put them on.

Falling back in love with my bike and rethinking about getting a new model

Keep you original bike, after 2010 all thd bikes are too tame, with the eco mode map and ktrc.... You cannot experience the PCV and your flies out on newer models, my dealer keeps pushing me to trade in, with all the time and money i put into it, i will not sell my bike, like you said, i am falling back in love at every start of the riding season...