Home made Radiator screen - Kawasaki Versys Forum
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post #1 of 4 (permalink) Old 12-17-2017, 07:25 PM Thread Starter
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Home made Radiator screen

After pricing out radiator guards and being somewhat shocked at the pricing of these units I decided to search the web for ideas. Setting in on my first prototype I used 3/4" x 3/4" x 1/6" angle aluminum for the frame riveting it together and using some decorative stamped aluminum sheet I sourced on Amazon for the guard itself. One 5 foot stick of the angle did the trick. First time out on this so I really don't know how it'll hold up, but for less than $25.00 and something to do on a very cold rainy weekend I figured what the hell. This is on a 2014 Versys.

I started out measuring the outside of the radiator and figured 16.5 x 6.5 inches would give me the frame required to cover the entire radiator. I fabricated four brackets to fasten the unit to the bike. Two brackets made from the 3/4" angle stock and two made from some 1/2" x 1/8" flat aluminum stock on the top of the guard. 1/8" rivets with back up washers and the flat stock on the inside to give the screen some rigidity. To fasten the guard underneath I removed the two 5mmx 1.o (10mm head) bolts and used longer 25mm bolts then another nut and lock washer. For the top brackets I "field measured" and bent the flat stock at a 90 degree angle and riveted it to the guard and used a self tapping hex head screw I secured the brackets into the frame gussets on each side. Additionally I notched out on the right side of the guard (right as sitting on the bike) to allow room for the radiator cap and the lower hose connection. I also had to use a 30mm 5mm x 1.0 bolt and a 10mm long plastic spacer on the lower left side "fairing" to stand it away from the guard just enough to not place pressure on both. Hopefully the pictures show all this. I'll do a follow up review after I put some miles on the set up and may be paint it flat black. But for now it'll be as is.
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File Type: jpg IMG_4166.jpg (73.3 KB, 111 views)
File Type: jpg IMG_4169.jpg (53.9 KB, 107 views)

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Last edited by 2linby; 12-17-2017 at 08:53 PM.
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post #2 of 4 (permalink) Old 12-18-2017, 01:11 AM
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Looks great, good work sir! I too am a big fan of DIY mods on my bike.


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Jeff Reichel Palmer, ALASKA
1 Tim 6:11-12 "FIGHT the GOOD Fight"
There is no inappropriate temperature to ride a motorcycle…just inappropriate layers of protection.
2011 ADVersys
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post #3 of 4 (permalink) Old 12-23-2017, 11:48 AM
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Originally Posted by 2linby View Post
After pricing out radiator guards and being somewhat shocked at the pricing of these units I decided to search the web for ideas. Setting in on my first prototype I used 3/4" x 3/4" x 1/6" angle aluminum for the frame riveting it together and using some decorative stamped aluminum sheet I sourced on Amazon for the guard itself. One 5 foot stick of the angle did the trick. First time out on this so I really don't know how it'll hold up, but for less than $25.00 and something to do on a very cold rainy weekend I figured what the hell. This is on a 2014 Versys.

I started out measuring the outside of the radiator and figured 16.5 x 6.5 inches would give me the frame required to cover the entire radiator. I fabricated four brackets to fasten the unit to the bike. Two brackets made from the 3/4" angle stock and two made from some 1/2" x 1/8" flat aluminum stock on the top of the guard. 1/8" rivets with back up washers and the flat stock on the inside to give the screen some rigidity. To fasten the guard underneath I removed the two 5mmx 1.o (10mm head) bolts and used longer 25mm bolts then another nut and lock washer. For the top brackets I "field measured" and bent the flat stock at a 90 degree angle and riveted it to the guard and used a self tapping hex head screw I secured the brackets into the frame gussets on each side. Additionally I notched out on the right side of the guard (right as sitting on the bike) to allow room for the radiator cap and the lower hose connection. I also had to use a 30mm 5mm x 1.0 bolt and a 10mm long plastic spacer on the lower left side "fairing" to stand it away from the guard just enough to not place pressure on both. Hopefully the pictures show all this. I'll do a follow up review after I put some miles on the set up and may be paint it flat black. But for now it'll be as is.

I dont think it has enough air flow for the hot summer days. let us know how often the fan goes off in the summer. Otherwise looks very cool !
I bought one from aliexpress for $15. link:

https://www.aliexpress.com/item/For-...311.0.0.xnkSIk
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post #4 of 4 (permalink) Old 12-23-2017, 01:50 PM Thread Starter
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Originally Posted by vaulter View Post
I dont think it has enough air flow for the hot summer days. let us know how often the fan goes off in the summer. Otherwise looks very cool !
I bought one from aliexpress for $15. link:

https://www.aliexpress.com/item/For-...311.0.0.xnkSIk

Yes I am aware of this potential. The Northwest rarely gets extremely hot and I rarely ride in city traffic for any extended period of time. But it is a potential concern that I am aware of. Thanks!

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