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November 6th, 2009, 09:44 AM   #1
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2009 hard parts radiator guard mounting

All,

When I bought my new 09 570 I mounted a set of hardparts radiator guards for obvious reasons. I followed the instructions given in the package, and the only obvious thing that I had to do was trim the top right side of the guard to clear the cable guide.



It wasn't until after returning home from FR 3 and Idaho where I threw my bike down a a hill that I discovered that my right side radiator and guard had been smashed in pretty good. Long story short I also discovered that all 4 rubber isolation gromments were destroyed. My KTM mechanic friend pointed out to me that the mount had taken up over 3mm of the mounting tower or pin, and that by just using the stock mounting hardware the rubber gromments, in addition to getting destroyed from over compression, were not able to perform their primary function of isolating vibration.





So a quick trip to Scott's performance products and I had the washers, .450" outside diameter x 6mm inside diameter and 1.5mm thick, I needed as well as the bolts, 6mmx16mm.





The stock 6mmX12mm bolts are self tapping bolts, that means about half of the bolt is not gripping the threads. Since the radiator guard is 3mm thick, I was going to use two of the 1.5mm washers at each mounting location. I checked the depth of each mounting pin, and the shallowest were the lower's with a depth of 16.5mm. This was of no consequence as I was adding 3mm of washers, and the stock washer that's under the gromment is about 2mm thickness.





Before installing the new hardware I did run a tap into all the mounting holes to clean out the powder coating and other junk from the threads that had not been used yet. My guess is that the self tapping screws are used from the factory for just the same purpose.



Next, I placed two 6mmx1.5mm washers down inside each radiator mounting gromment and then installed the radiators over the guards and used the new 6mmx16mm bolts to secure them. The result was radiators had the same flexibility as stock.



Even though the stock guard on the right side was ruined in the fall, it had served it's purpose as I am sure without it at least two tubes would have been torn off the bottom tank in the fall, in the middle of no where.
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November 18th, 2009, 08:57 AM   #2
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RE: 2009 hard parts radiator guard mounting

just fitting my ones that i got courtesy of kirk 'bikebarn' beckmans generous donation to the FR3 raffle.

see what you mean about everything particularily having to grind off a couple of mill.

checked out the photos in the instruction in a bit more detail and the sneaky buggers have just removed the cable guide rather than cut the guard from factory to fit with it in place.
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November 18th, 2009, 10:37 AM   #3
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RE: 2009 hard parts radiator guard mounting

fitted mine up doen exactly as dale suggested and they are spot on.

only thing i've done different is that i didnt have to grind the guard to fit around the bolt.

i just removed it!

well to be exact i put a couple of extra cable ties around the cable guide then removed the bolt. then when you tighted up the guards / rads the part of the cable guide where the bolt is gets pinched between the guard and the frame and is held in place.

even if it does work loose on a ride its not going anywhere and its held in place by the cable ties.
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