KTM Radiator Wear

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1/13/2018 10:30 AM

The shrouds on my 2016 KTM 150sx wearing a line in the aluminum radiator. I noticed it last season and put some metal tape & foam on the spot. That has worn through.
Has anyone else had this issue? What was your fix? I’m going to try glueing a rubber pad in this spot. I’d hate to see it wear through.Photo

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1/13/2018 5:36 PM

My fix would be to remove plastic from the reenforcement part so it clears the radiator. Or add a washer or 2 between the radiator and the plastic where the bolt goes. Should give clearance.

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2009 Kawasaki KX450F
2009 Kawasaki KX250F
2002 Suzuki GSXR 600

1/13/2018 7:46 PM
Edited Date/Time: 1/13/2018 7:47 PM

Only true answer is to weld it. I agree with acid dreamer maybe some washers are needed for clearance. At least use rubber. It won't go through it you use thick enough stuff.

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1/13/2018 10:06 PM

If it’s the plastic that’s wearing into it, can you just cut it back?

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1/14/2018 2:48 AM

Had the same Problem on my 150 SX.
This Marks was very Deep
I put Liquid Metal over this Pressure Marks ,does not really look good
but it works

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1/14/2018 2:55 AM

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1/14/2018 2:55 AM

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1/15/2018 4:45 AM

Thanks for all the replies.
It's a tough spot to cut any plastic away or add spacers to the fasteners. It's the bottom edge of the shroud and it only contacts the radiator when it flexes (probably when cornering). If the shroud was longer it wouldn't even touch. You can just see the lower edge of the radiator in the attached picture.
I'm surprised more models don't have this issue since they all share the same plastic.

Photo

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1/15/2018 5:04 AM

Is it cutting into the radiator? Your picture looks like its just cutting the foam. I have a hard time believing plastic is cutting alumimum.

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2009 Kawasaki KX450F
2009 Kawasaki KX250F
2002 Suzuki GSXR 600

1/15/2018 7:11 AM

Acidreamer wrote:

Is it cutting into the radiator? Your picture looks like its just cutting the foam. I have a hard time believing plastic is cutting alumimum.

It’s from the vibration, I’ve had it happen on my 125.

What if you heat the plastic slightly and bend it away?

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1/15/2018 7:27 AM

Acidreamer wrote:

Is it cutting into the radiator? Your picture looks like its just cutting the foam. I have a hard time believing plastic is cutting alumimum.

CarlinoJoeVideo wrote:

It’s from the vibration, I’ve had it happen on my 125.

What if you heat the plastic slightly and bend it away?

Yes thats an option.

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2009 Kawasaki KX450F
2009 Kawasaki KX250F
2002 Suzuki GSXR 600

1/15/2018 10:43 AM

Acidreamer wrote:

Is it cutting into the radiator? Your picture looks like its just cutting the foam. I have a hard time believing plastic is cutting alumimum.

CarlinoJoeVideo wrote:

It’s from the vibration, I’ve had it happen on my 125.

What if you heat the plastic slightly and bend it away?

That's a good idea. I'll look at it tonight and see what can be done.

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1/15/2018 5:00 PM

Acidreamer wrote:

Is it cutting into the radiator? Your picture looks like its just cutting the foam. I have a hard time believing plastic is cutting alumimum.

I cleaned the foam off and took another picture. You can see the wear mark in the aluminum and on the edge of the shroud. It’s happening on both sides of the bike.Photo

Photo

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1/15/2018 7:27 PM

Acidreamer wrote:

Is it cutting into the radiator? Your picture looks like its just cutting the foam. I have a hard time believing plastic is cutting alumimum.

Bent206 wrote:

I cleaned the foam off and took another picture. You can see the wear mark in the aluminum and on the edge of the shroud. It’s happening on both sides of the bike.Photo

Photo

Off topic, but where did you get those carbon engine mounts?

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1/16/2018 5:50 AM
Edited Date/Time: 1/16/2018 6:53 AM

Acidreamer wrote:

Is it cutting into the radiator? Your picture looks like its just cutting the foam. I have a hard time believing plastic is cutting alumimum.

Bent206 wrote:

I cleaned the foam off and took another picture. You can see the wear mark in the aluminum and on the edge of the shroud. It’s happening on both sides of the bike.Photo

Photo

CarlinoJoeVideo wrote:

Off topic, but where did you get those carbon engine mounts?

They are the stock mounts with "carbon look" background material. Nothing factory here! Ha Ha
We have a lot of extra time on our hands during the winter months in New England.
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