Join Date: Dec 2005
Location: Squamish B.C Canada
posted a reply earlier but it didn't go through, must be a latent talent of mine. so here goes again and crossing my fingers. sorry but no pics. a digital camera is on my wish list. first measure your rad so you know how much area to cover. i found the smallest paper tray at staples to be large enough to do the job. it is a silver/ grey with a matal frame around each of the side pieces and bottom which is bent up to form the back. the frame work is spot welded at appropriate places. if you have a dremel your job is going to be very easy. i used a file and hack saw blade to cut the welds.
next, get some cable ties, eight will do, and washers. another eight will do. i used seal washer ( 4) for the back side of the rad to eliminate metal to metal contact but it may not be all that neccessary in the grand scheme of things. after taking apart the tray, measure how much needs to be cut off the back portion of the try. the finished rad guard will be a mesh that has re-inforced side and bottom edges. the extra side pieces or the cut off portion can be used for the oil cooler.
now the fun begins. flashlite required. look at the sides of the rad from top to bottom. there is a verticle line of slots that the cable ties can go through easily. thread them through from back to front so there are four ties sticking out the front of the rad. measure the distance between them and make appropriate holes in the wire mesh. the mesh when installed will not touch the cooling fins. the frame work is just big enough to go across and rest on the side tanks. i used some insulating tape on the frame work edge to avoid metal to metal contact again. just slide the mesh over the ties and put a washer on the tie. slide another tie onto that first tie. tighten as needed. trim your ties and have a beer.
as for the left over pieces of mesh, i used the cut off portion to put behind the factory mesh of the oil cooler. just cut it to size and the factory mesh will hold it in place. you might want to paint the mesh before hand, it is up to the individual, i didn't. the finished product should offer protection from most hazards without getting into great expense and weight. i see the mesh as sacrificial, same as a helmet. it can be replaced easily after an oops.
i hope i haven't been too long winded but i wanted to explain as well as could be. keep the shiny side up
05 / 650 in blue