Both top radiator tabs broke on my 2002. I fired up the wire feed, fed in some aluminum wire, added a little argon, and welded the tabs back on. Instead of just welding on the tab as I would if this were steel, I built the weld on each side, even into the hole, and then used a dremel to clean the weld down to insert the rubber mount. When I installed the radiators, I sprayed the inside of the hoses with WD40 to ensure they slipped onto the radiators all the way, and installed the radiators before I tightened the hose clamps.
Now, as most folks know on this site, I ride more than the average bear, burning 10-15 gallons of gas on a normal weekend, so I'm a pretty good test for the fix. After almost 6 months, the fix has remained. One caution: When using an aluminum wire feed on your radiators, use a go-dark helmet, as one touch of the wire lead to the radiator tube will result in more repairs. I have been fortunate to avoid such an occurrance, but have always been very careful during repairs.
Good Luck
Rick
