Chinese/GPI rad install KX500

[Burle]

I needed some rads and was looking around to see how guys are making these notoriously poor fitting rads line up and couldn't find too much. OEM rads are an arm and a leg and I got these off eBay with a rad hose kit for $102. People say these are rads bend easy but looking at them the aluminum around the outside is about twice as thick as the stock rads, maybe a crappier aluminum? Took some pictures when I installed them.

20200302_163416_resized.jpg (188.16 KiB) Viewed 8392 times

Left side had two holes that lined up well

20200302_163508_resized.jpg (172.49 KiB) Viewed 8392 times

Right side could only make one hole work so I chose the on that made the rad shroud plastic holes line up best

20200303_113113_resized.jpg (225.51 KiB) Viewed 8392 times

20200303_124122_resized.jpg (187 KiB) Viewed 8392 times

Cut off the bottom tab and spoolgun welded on a piece of 1/8"x1" aluminum long enough to suit. I vise gripped a piece of steel under my weld so the aluminum didn't drop out on me as I welded it

20200303_124611_resized.jpg (180.59 KiB) Viewed 8390 times

I did the exact same thing for the bottom mount on the right side rad

[Burle]

20200302_163533_resized.jpg (195.66 KiB) Viewed 8389 times

20200303_172434_resized.jpg (132.36 KiB) Viewed 8389 times

20200303_175636_resized.jpg (175.85 KiB) Viewed 8389 times

20200303_175643_resized.jpg (169.65 KiB) Viewed 8389 times

I just used a die grinder on the right side middle mount as there was enough material there to accommodate, then welded up where half of the old hole was

20200303_175936_resized.jpg (194.38 KiB) Viewed 8389 times

Plastic holes all lined up well.
I didn't see anyone complaining that the inlets and outlets don't line up but I guess we'll see when I get the engine in

[Sandblaster]

Very nice write up. Thank you for posting.
If I get the time in the next few days I will post some similar pics to yours with a added twist
You are right, the aluminum on the Chinese rads is not as strong as the OEM.
But good luck finding good OEM's..
Besides the holes not lining up you will also find that the mounts like to crack and break off.
I hope I can find some pics showing you how to reinforce them..

I also see that your upper mount for the pipe is busted. If you need help with the location I can help you out..

http://www.oem-cycle.com/forum/viewtopi ... 115&t=1532

[Sandblaster]

Here is some pics of some Myler rads that have gussets on the tabs.
It might be worth doing while you are at it..

1583297439973_0388854492_2c3e9e66.jpg (101.27 KiB) Viewed 8374 times

1583297454448_0539882296_2c3e9e66.jpg (97.16 KiB) Viewed 8374 times

1583297471432_0480010492_2c3e9e66.jpg (94.5 KiB) Viewed 8374 times

Another issue you may run into is the bottom left inlet tube,
You may have to do some adjusting and trimming to get it to work.

[Burle]

Braces look like a good idea, I'll try and do those for sure. I saw myler's has rads for the K5 as well but I need all my arms and legs for riding. If I do run into issues with the spouts when I get the engine in I'll update.

[Sandblaster]

Excellent!
Start a new thread under Bike Builds and take lots of pics

[Burle]

I hadn't noticed the bike builds section, I'll have to start a few posts in there, too many pictures to sort through though

[Burle]

Tig welded on some mount braces, hopefully won't have to deal with cracks in the future

20200331_143302_resized.jpg (165.84 KiB) Viewed 8270 times

20200330_235936_resized.jpg (180.55 KiB) Viewed 8270 times

[Burle]

Cylinder is away getting repaired/replated, so I just used spare empty cases and cylinder to mock up and finish radiators.

Left side lower spout didn't line up at all, cut pipe at the two lines and welded back together

20200331_181859_resized.jpg (249.41 KiB) Viewed 8269 times

Had some contamination issues with the weld, aluminum is hard, I have faith it'll seal though

20200331_214825_resized.jpg (215.31 KiB) Viewed 8269 times

20200331_215324_resized.jpg (228.15 KiB) Viewed 8269 times

All the other spouts lined up pretty well and the hoses in the kit I bought were proper length and had the right bends in them

[Burle]

20200331_152128_resized.jpg (201.23 KiB) Viewed 8269 times

The aluminum where the rad shrouds mount was too thick for the little nut clips

20200331_142137_resized.jpg (155.34 KiB) Viewed 8269 times

Just shaved them down a bit

20200331_142434_resized.jpg (140.67 KiB) Viewed 8269 times

20200331_143135_resized.jpg (152.97 KiB) Viewed 8269 times