[2cati]

2cati, summarizing what you did here... You just simply removed the plastic washer and then didn't "snug" down the bolts but instead used loktite to keep them from falling back out on you?

That was my initial intent but once I removed the plastic washers, there is enough clearance for the plastic side panels to float while tightened properly - I still use loctite. You can see in the photo below the shoulder of the screw extends past the plastic, so when tightened down, the plastic will float. Hope this helps.

 

[dcpppf]

Maybe a stupid question here... But as far as I can tell the only mounts causing the issues are the ones at the top of the radiator. Not the ones on the sides.

Thoughts on only modifying those top mounting points but leaving the side ones "solidly" mounted?

 

[2cati]

All points of contact from the fairings would exert pressure on the radiator according to the video - why don’t you just leave out the top 2 and move your tank downward and see if the radiator moves…

 

[dcpppf]

Not with the bike right now just thinking this through.

The photos that made the damage pretty clear were directly under the top two mounting points it looked like. Sure the side ones are feeling the pressure too... But from what I've seen those appear to be within the limits of the radiator. Where as the top two are the only two causing problems

 

[dcpppf]

Thinking about just replacing the four rad bolts with these... Figure they'll offer some flexibility and maybe soak up some vibs.

Amazon.com: uxcell 30Pcs 5mm Black Plastic Rivets Push Type Panel Retainer Fastener Clip for Car : Automotive

Buy uxcell 30Pcs 5mm Black Plastic Rivets Push Type Panel Retainer Fastener Clip for Car: Clips - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

www.amazon.com

 

[Spartacus]

Dunno about those fasteners bro ... they hold light weight panels in place. Those are on my truck to hold the plastic cover on the bumper, like 16 of them. The rad is way heavier and you can only use a max of 4 of them right?

 

[dcpppf]

The main purpose of those four bolts connecting the fairings to the rad are to support the fairings, not the other way around. The bracket under/bottom of the rad and at the top won't be touched. Just those four holding the fairings from "blowing out" at speed.

 

[Schism75]

I just did this as a preventive measure being new to the KTM game. My rad appeared to be intact @3500 miles. I removed all 4 plastic washers from the fairing front bolts, used loctite (blue of course), seated them fully, then backed off a quarter turn. I'm confident this will work but only time will tell. Thanks to all that contributed to this inevitable nightmare and I hope this is the end of radiator problems.🤞

 

[nosurrenda]

Just to let you all know, KTM got back to me advising they are looking into this issue. I'm pretty sure the company is aware of info on this forum.

 

[12ACE]

Just to let you all know, KTM got back to me advising they are looking into this issue. I'm pretty sure the company is aware of info on this forum.

Did you hear anything else from them? I've just had mine repaired. Leaking beneath both mounts.

 

[nosurrenda]

Did you hear anything else from them? I've just had mine repaired. Leaking beneath both mounts.

Unfortunately I'm a lone voice in this unwinnable battle, so no they haven't done a thing since. All I can do is urge all SDR owners to hound KTM in their respective countries. Why don't our USA siblings engage the NTSA and see if they can trigger a recall?

 

[Mirage]

For completeness, to submit/report a safety concern via NHTSA, you can go here.

 

[CUL8R]

I have not had a Radiator problem yet but after 2.5 months waiting to hear from KTM about
my swollen and blistered gas tank they said too bad you can buy a new for full price. Ducati
replaced 2 tanks on my Sport Classic out of warranty no questions asked The 3rd Gen
went to a steel tank so KTM knows it's an issue they just don't care.

 

[2cati]

My tank was off for my 30kkm Maintenance 2018 SDR) and when I put it back I was shocked how much movement there was - as others have mentioned those round rubber mounts are so loose in the tank “cups”…so I decided to build them up with tape (for hockey equipment) - made a huge difference in reducing the movement..

 

[CUL8R]

Looks like you found a Carbon tank cover that fits?

 

[Menso]

My tank was off for my 30kkm Maintenance 2018 SDR) and when I put it back I was shocked how much movement there was - as others have mentioned those round rubber mounts are so loose in the tank “cups”…so I decided to build them up with tape (for hockey equipment) - made a huge difference in reducing the movement..

Pretty much my solution, I used tape strips for windows to stop draft coming in. Tends to be a few mm thick which fills the gap perfectly. Just lay a strip inside the tank cup and keep it short, or it's visible from the riders position.

 

[Eric j]

Hello
It happened on my 15 sdr
I had to buy a 700$ replacement radiator
I looked at everything carefully , what i found(on my bike) was that the lower radiator support bracket was loose.
The bolts were tight , but the rubber grommets were cracked so the bracket had play in it, wich left all the weight on the top brackets , where the leak was.
Those little grommets are cheap, but cause a lot of damage.
Check your bottom brackets !!

 

[dcpppf]

Hello
It happened on my 15 sdr
I had to buy a 700$ replacement radiator
I looked at everything carefully , what i found(on my bike) was that the lower radiator support bracket was loose.
The bolts were tight , but the rubber grommets were cracked so the bracket had play in it, wich left all the weight on the top brackets , where the leak was.
Those little grommets are cheap, but cause a lot of damage.
Check your bottom brackets !!

Any photos by chance? I've heard some folks talking on the facebook group about replacing these with generic honda ones with good results. Just curious how bad yours got in such a short amount of time.

 

[Eric j]

Sorry i don't have pictures
It hapened last year
While changing the radiator , i noticed the bottom bracket(still bolted to the engine) had a lot of up and down play, so the radiator had no support from the bottom
The grommets were flattened really bad
After replacement , the bracket didnt have any play in it.

 

[Joe1290]

My grommets were missing, so were replaced entirely at 96,000km. They seemed ok at 81,000km when first rad repair was done.
This is that radiator now at after 132,000km. Too many wheelies they said.