Radiator Protection - and Custom Acerbis 6.3 gal Tank Mounts

Ok, so we are going to ride the OBCDR this summer and I really don't want to worry about my radiators getting damaged. I have the acerbis 6.3 gal tank on the bike which offers some protection on its own but...I've read where the tank can flex enough in a crash to still bend the radiators so I decided to install some radiator guards/braces. Originally I was going to fabricate my own braces, after poking around the net a bit I came across the Unabiker radiator guards for the XRR and they look pretty bulletproof. For all the time it would take to fabricate something like that from scratch I decided to just order a set.

The gaurds came in just a few days after I ordered them. Very well packaged with all the included hardware ect. They are very well made also. Top notch piece of kit

Installation takes a little time a patience, I had to use several different tools to get them installed (1/4" drive with a universal and a 4mm alen on the end....all taped up with electrical tape to make it stiff enough to get bolts started). But once they are installed you have some VERY strong guards! I'm really impressed with the fit and quality of these guards.

I'm also running a KTM radiator fan, I had to cut a small notch in the fan housing to clear one of the bolts on the unabiker guard and then it slipped right back into place. I also had to drill a hole in the gaurd to bolt the lower part of the cooling fan down. Easy enough mod.

Time to re-install the tank......Dang. The acerbis sahara tank comes with two metal brackets that support either side of the tank. They bolt to the front engine mount and run out to the tank. They really didn't fit/support very well in the first place and now with the unabiker guards installed they didn't fit at all.

Soooo.......Time for another mod. I decided to fabricate a tank brace that would hold the tank out a tiny bit on each side to keep it from rubbing on the gaurds when full (the tank expands a bit when full), and also to offer another degree of protection for the radiators in the event of a crash. I made the brace attach at the front engine mount bolt again but kept the whole unit one piece to make it strong. I drilled and tapped the brace so the lower tank mount bolts thread right into the brace. Ended up not bad, good fit and out of the way.

I still have to take it back off and pretty it up a bit (smooth/round the corners ect) and then powder coat it black. Between the Unabiker guards and the new brace my radiators shouldn't give me any problems.





Here's a shot of the guards installed on the bike. Where each bolt head is located a solid metal rod goes across to the other side of the brace.




Here you can see how the back of the two guards are connected. There are two small rods that connect the two guards (here you can see the lower one). There are also 5 large rods that brace each guard, three on the front and two on the back.




Here you can see the small notch I had to trim in the KTM radiator fan to make it fit with the guards. This was the only mod I had to make to the fan unit. Sweeet.




In this shot you can see where I drilled the hole in the right guard to bolt the bottom of the fan unit in place. Also note that there is one of the 5 metal rods missing on the right radiator. I had to leave the upper back rod off to fit the fan in place. The guard is still super strong and I'm not worried about the one missing rod.




Here is the front of the guard. You can see the metal rods behind the front grill. In this picture you can also see my home built lower sahara tank mount. The mount holds the tank out just slightly so the tank doesn't rub on the rad guards.




Better view of the tank brace, it tucks in close to the frame and won't be in the way.




Here you can see how the tank brace/mount mounts up to the front engine bolt.




Here's a shot of the brace that comes with the sahara tank. Once the
Unabiker guards were installed I couldn't get them to line up properly
any more. The new brace will offer better protection anyways.

I
still have to get them cleaned up and powder coated but thought this
might give other people and idea for a lower tank mount if they are
going to run these guards.







UPDATE: I had enough interest in the braces to make a batch to sell. If your interested in a "Tanker Brace" CLICK HERE

Hodakaguy

Looks sweet. Thats what I'm looking for. All my fellow riders with tanked up radiators. That unit should do the bisso. BTW the skid plate is that home made or can you buy em.

Thanks. The skid plate is a Ricochet, available at the Dual Sport Armory: www.dualsportarmory.com. Make sure you use their XR650R coupon for a discount!

The skid plate is a very nice unit and bolts right up.

Hodakaguy

Cheers that babys in the shopping trolley

Hodakaguy...

Nice looking set-up. I did the Devols and the Unibiker setup looks way better.

Nice work... I'm in interested in your fan set up. Can you share with us some of the details of that mod... What year/model are you getting the fan from? That looked like a pretty simple mod for a little more reliable cooling.

KTM265 wrote:Nice work... I'm in interested in your fan set up. Can you share with us some of the details of that mod... What year/model are you getting the fan from? That looked like a pretty simple mod for a little more reliable cooling.

Here's a link to the fan: CLICK HERE

You might want to watch ebay, I've seen the same fan go for $50 new. There are other options on fans also but some I've read don't hold up very well (like using converted computer cooling fans). I like the shroud that is built in to the KTM fan, it fits up tight to the radiator so when the fan kicks on it pulls all the air through the radiator and not just around it. The shroud is also bigger than the fan itself so it increases the surface area that air will be traveling across. There is a rubber flap on the top of the fan that acts as a check valve. While the fan is off air can flow through the flap and increase cooling, while the fan is on the flap is pulled closed and air has to go through the fan.

The fan comes in a kit that has some parts you won't use. Some people try to install the temp switch so the fan will operate with engine temp, I didn't really find a place to intall a thermo switch that I liked so I run the fan manually.



Here is the switch assy that I use to control the fan. It's build by Highway Dirt Bikes and is a top notch unit! The switch assy replaces the clutch or brake perch clamp and has two waterproof switches in it. The main body/clamp is machined out of solid aluminum. I use the upper switch to control my 8" race light and the bottom switch to control the fan. The switches are in a perfect possition to be operated by my thumb while riding. If I hit a long hill, I'm doing a lot of slow riding, or just stuck in traffic during a long light on a hot summer day I can just pop the fan on for a bit.

Is the fan setup really necessary? Probably not but for the price it's worth the piece of mind to have it if I need it.

Hodakaguy

Thanks, I got it added to my list of mods...I hope to get all of them done before the serious riding season starts in.

yeah that's what I'm trying to do also, get all the mods/maint done before the real riding season begins.

I'm ready to ride!!!

Hodakaguy

My KTM is in the shop right now getting some little things done...Should be ready for the back roads and gravels next week. The XR I'm setting up just for the trails...

I only have the Ktm fan that I want to mount on my Xr. Maybe I should have a look on the mounting plate that you have that looks realy nice

JossaXr wrote:I only have the Ktm fan that I want to mount on my Xr. Maybe I should have a look on the mounting plate that you have that looks realy nice

I was running the fan before I got the guards. It fits onto the radiator just fine.



I took a dremal tool with a small cut off wheel and cut the bent part of the emissions tabs that are on the radiator. You're left with a short piece attached to the radiator that sticks straight out. Then I just slipped the fan over the tabs, drilled some holes in the tabs to line up with the fan, and made a small aluminum piece to hold the bottom of the fan in place.

Worked great. No guards needed.

Hodakaguy

Brace looks nice-n-beefy

I think the addition of a fan with the Megatanks is a good idea due to the reduced airflow. Really like the shroud on the KTM fan you used, will have to add it to my list of to-do mod's.

I have some "Tanker Braces" for sale now. You can see the details here: CLICK HERE

Hodakaguy

So my guards arrived today in the post. Payed the postie the tax and off to the shed. First impression was, wow bit tinny, Had a read through the instructions and started to take off all bits that were specified. No photos in the instuctions except a small picture to show you where the braces go. Had to read a few times the instructions over as I went but they were very well explained. Got to the stage of putting the little braces that hold the two guards together. Not much room in there. The exhaust and motor made it very difficult at times to place the little bolts in place and line up the holes. Me, I'm not very handy when it comes to mechanics, and bannana fingers also don't help. I mananged to place all the bolts except the last three with a hex screw driver and small alen key. The last three were impossible with my limited resources. I quick trip to a friends place to borrow an alen key with a ball end and the last three bolts were in place. Tightening all the bolts after they were all in place was easy with this alen key and a pair of pliers to get abit of purchase. Took about three hours in total which i'm not proud of, but I'm I happy I managed without sticking a hole in one of the radiators or losing my head when I couldn't get a thread take. A smoke calms the nerves and gives you a break
Once all bolted in place the rads seem to very well protected. I changed the bolts that hold the plastic guard to the radiator because the originals weren't long enough after the guards were in place. I even unintentionally dropped the bike when I put the stander down after everything was back together opps :gahh:In all, very happy with the unabiker guards. Hope they save me some money in the future.

Are there any more Tank Brace up for sale? I want one to my new Acerbic tank.

JossaXr wrote:Are there any more Tank Brace up for sale? I want one to my new Acerbic tank.

I have another batch almost finished except for welding...I really need to get off my butt and get them finished up (to many irons in the fire )

I'll post up as soon as I have another batch ready to go.

Thanks

Hodakaguy

Hodakaguy wrote:

JossaXr wrote:Are there any more Tank Brace up for sale? I want one to my new Acerbic tank.

I have another batch almost finished except for welding...I really need to get off my butt and get them finished up (to many irons in the fire )

I'll post up as soon as I have another batch ready to go.

Thanks

Hodakaguy

Sign me upp for one

Sorry to bump such an old thread but these things are great! I went over and checked out the rad guards but I really think with your addition the bottom of the radiator will be much better protected.
Are they still around or are you planning on making more?+
Thanks Shoot me a PM if you get a chance

Tree,

I've sent a PM for you to Hodaka because I'm almost sure you cannot.
Those braces are nice, I've read only good about them, and he made plenty already.
No idea if he visits here often or not, but when he does he'll find the pm and no doubt will contact you.

Cheers!

BuRP wrote:No idea if he visits here often or not, but when he does he'll find the pm and no doubt will contact you.

He'll get it and take care of you!

Hi
Are there any of the radiator braces still for sale?????
They sound good and I cant find anyone to do anything like this in Australia.
Also if there are some available, how much for the brace and shipping to Aus.

Thanks

Sorry for the late reply here. Yep I'm still making the braces and have them boxed and ready to ship.

I sell most of them through ADVrider here: http://www.advrider.com/forums/showthread.php?t=435561

Shipping to Australia isn't to bad through the USPS...$14.00

Let me know if your interested in a brace...a PM through ADVrider is the best way to get a hold of me.

Hodakaguy