Help! I've just broken the two bottom mountings on my XT660R 2008 radiator whilst on a 6000km offroad trip to Uluru in Australia.

I didn't hit anything or drop the bike at all so all I can imagine is that the amount of corrugated and rocky roads we traveled on must have snapped them. This is now the second radiator I've done this to and I'm wondering if there is a mod to protect the radiator in the future. I'm thinking an additional bracket perhaps?

Any suggestions would be greatly appreciated, thanks.

I know you're in Aus but have a look at this UK web diagram to give an idea of what you're dealing with.

https://www.ajsutton.co.uk/genuinepa...09/frame?uID=0

For a fix-in-the-field I'd use zip/cable ties to pass from the eyelets of the rad back around the frame's down tube.

As for a permanent fix, I weld a larger cross bar and with a bigger contact patch to the frame. Remember to remove the battery and disconnect the ECU for circuit protection whilst welding.

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I have a lot of growing up to do. I realized that the other day inside my fort.

Hey Chalk Two

I see what you mean with the crossbar. It is probably the short cross bar that is letting the radiator wiggle from side to side which breaks the lugs as it's only the bottom ones that have broken on both radiators. I guess I'd als have to weld lugs on the outside of the raiator too to make this work huh?

having had a re-read of this I'm wondering if the rad is fixed,also, at the top? There appears to be a top eyelet on the radiator schematic. If that was missing then that might explain why the lower two mounts are stressed to failure.

__________________
I have a lot of growing up to do. I realized that the other day inside my fort.

The R radiator is fixed at 3 points,in a triangle.
Centre of radiator,at the top, to the downtube,also mounting for the guard,and the two at the bottom on a bracket which is attached to the downtube and is also the mounting for the guard

Hope that makes sense

thanks nikroc and in that case I'd have to ask Neil if his rad was missing the top mounting bolt allowing the rad to move and stress the lower two fixing points.

__________________
I have a lot of growing up to do. I realized that the other day inside my fort.