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Radiator Damage Prevention-450,500,700,750by Singlemalt, 2010-05-28
After having my front end plastic pushed back due to a flipped quad I discovered that I also had an upper radiator puncture that could have been prevented. The cosmetic damage was easily fixed. There is an extended plastic tab on the backside of each lower headlight pod that lines up perfectly with both upper corners of the radiator. Any front end collision or force that pushes the plastic back a little has the potential to puncture the radiator resulting in costly repairs and a long walk or tow job. The fix is quite simple and can even be performed with the headlight pods still on the quad if you have a good grip and a long reach. If the headlight pods are out or the front end plastic is off it is very easy to cut the offending tabs off.
The offending plastic tab as seen mounted on the quad, picture by Glenlivet:
Another shot with the front end plastic off:
And This One:
Both Cut Off:
A picture of the tabs with the headlight pod out courtesy of Dr Z:
Another method to remove the tabs while still on the quad. Glenlivet used a pair of tin snips and a good grip.
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