MudInMyBlood Forums
Go Back   MudInMyBlood Forums > Brand Basics > Kawasaki > "How To's" > Engine & Exhaust

Reply
 
LinkBack Thread Tools Display Modes
Old 04-05-2009, 03:13 PM   #1
Wright Guard
 
phreebsd's Avatar
 

Join Date: Dec 2004
Location: Bama
Posts: 6,753
Images: 37
phreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to all
How To: Relocate Radiator - Brute Force 750

If you hit the mudholes a lot and over heat afterwards, relocating the radiator will save you the grief and possible engine damage from overheating on the trails.

Removing The Radiator
Start by removing both front tires. Then remove the screw on each side of the radiator shroud. There is one on each side. This is to make room to remove the radiator fan.



Now remove the 3 10mm bolts holding the fan on. Disconnect the drain tube and also the electrical connector.





Now that the fan is out go ahead and remove the upper and lower hoses from the radiator and let it drain into a bucket. Remove the lower one first. Loosen the radiator cap to help it drain.



Now it is time to remove the radiator from the chassis. The radiator is held in place by 2 8mm bolts on the top hear the end corners. Just lift up the shroud plastic a little bit and u can get a 1/4" ratchet with extension up there to remove them. Once they are out the radiator lifts out of the rubber grommets on the bottom. Pull these rubber grommets out. You can use them in the brackets you make.

Put the fan back on now. you will need it there so that you take that space it occupies into account when fabricating your brackets.





Fabricating the brackets

We made 2 simple brackets to hold the radiator on the rack. The brackets are held in place by 2 U-Bolts on each bracket. The setup is very study.

We chose 1" x 1/8" flat bar steel. It comes in 3 foot lengths at lowes.
2 pieces are needed for this project. I bought 4 pieces so I made an extra set for BigP.



Each bracket was made in 2 pieces - a bottom piece and an upright.
For the bottom piece we started with a 12" piece of flat bar. We decided to build these brackets to hold teh radiator at a 50 degreen angle. I thought that looked best. Based on this your design may change.

On that flat bar we drilled a 5/8 inch hole to hold the rubber grommet the radiator sat in on the frame.



Once the holes were in place we measure off 2 inches on the drilled end and made a bend of approximately 40 degrees.



We then put the brackets on the rack and marked and drilled the holes for the u-bolts.



Once the bottom pieces were bolted on we set the radiator on to get 50 degrees slant. Once we had that I laid the back pieces up to figure how tall to make them.




The vertical pieces started out cut 11" with a bend 2" from the top at a approx 25 degree angle. We decided to use the same 8mm top bolts so a 7/32" hole was drilled then tapped with a 6mm x 1.0 tap.
(The curved marker line is marked where i decided to cut it off and round it)



The vertical pieces were then welded on.






The brackets were affixed to the racks with u-bolts and the radiator was put in place.











Making the Connections (hoses, vents, and fan connection)

Now that you have your radiator bolted into place now is a great time to hookup the fan. I found that you do not have to cut and extend the wires at all. i ran the connector from the fan down thru the shroud where the snorks exit. The connector was easily long enougn to reach its plug underneath. Also now is the time to hookup the fan vent thought it's likely not needed now.

You will need to remove the left side floorboard so that you can install the the lower radiator hose (3/4" I.D.).

Up above I decided to cut holes in the plastc rather than using the shroud. The bends the hose would have to make not to mention clearing the exhaust would have made the shroud a difficult entry point.












Once your hoses are connected back you now need to run the overflow tube. i had to go to lowes and buy 10ft. This was enough to run the tube from the radiator to the bottle as well as run the bottle vent all the way back up to the pod. THIS IS IMPORTANT TO DO if you take your bike deep..

This is what can happen if you dont extend the bottle vent!






Once you got everything hooked up it's time to fill up the radiator! Fill it up and run it with the cap off. Any air trapped in the system should work its way to the radiator. Keep filling up the radiator as the air bubbles are released.



Costs of Materials
4 pieces of steel - 24.00
10 ft vent tube (5/16")- 8.38
1 jug coolant - 10.00
13ft Radiator Hose (3/4 I.D.) - free

Total cost about 43 bucks
Time spent about 4 hours - we did not rush

There are many ways to do this project. This is the way we chose. i hope it helps someone out!








__________________________
2008 Kawasaki Teryx
31" Laws
Black ITP SS212's
Relocated Radiator
Maroon Primary
Yellow Secondary
MIMB Snorkels (dual 2" intake)
Rejetted
RaceDriven Sintered Metal Brake Pads
BigGun EVO Exhaust
Viper Max 5000 WideSpool with Amsteel Blue

TEAM ROLLIN' DEEP 2013

2008 Yamaha WR250R
phreebsd is offline  
Feedback: (7)
Reply With Quote Go to top
Old 04-05-2009, 04:38 PM   #2
Professional Mudder
 
Metal Man's Avatar
 

Join Date: Dec 2008
Location: Tupelo,MS
Posts: 1,798
Metal Man has a spectacular aura aboutMetal Man has a spectacular aura aboutMetal Man has a spectacular aura about
Good job on the relocate and write up Steve!! This will help a lot of folks out.

PS.....Dont forget to send yourself a sticker








__________________________
08 Brute Force 750
MIMB Snorkels with 2 1/2 Air Intake
28 Zillas n ITP SS112's
Manual Temp Gauge
6k HID's
VFJ Stage 3 Clutch
VDI Copperhead ECU
HMF Swamp XL

MIMB Ride at Rock's Bottom video link

Metal Man is offline  
Feedback: (4)
Reply With Quote Go to top
Old 04-05-2009, 08:40 PM   #3
Professional Mudder
 
Yesterday's Avatar
 

Join Date: Jan 2009
Location: Central Arkansas
Posts: 1,435
Images: 15
Yesterday is on a distinguished road
Yesterday is offline  
Feedback: (0)
Reply With Quote Go to top
Old 04-07-2009, 03:25 PM   #4
Professional Mudder
 
Yesterday's Avatar
 

Join Date: Jan 2009
Location: Central Arkansas
Posts: 1,435
Images: 15
Yesterday is on a distinguished road
yum. killian's.
Yesterday is offline  
Feedback: (0)
Reply With Quote Go to top
Old 04-07-2009, 05:13 PM   #5
Breaker of things
 
KMKjr's Avatar
 

Join Date: Jan 2009
Location: Middle Sackville, N.S. Canada
Posts: 1,445
KMKjr will become famous soon enough
Send a message via MSN to KMKjr Send a message via Yahoo to KMKjr Send a message via Skype™ to KMKjr
If you don't put your rad cap on until all the air is out (just fill it and leave it run at idle or slightly higher), it should not overheat. By putting the cap on you are causing an air lock in the system. Air from the system will naturally work to the highest point and by putting the cap on you are not letting it escape.








__________________________
2012 Brute Force 750i EPS
Bison Hunter Series front & rear bumpers, Eagle Eye HID's, complete orange anodized Ricochet armour
KMKjr is offline  
Feedback: (0)
Reply With Quote Go to top
Old 04-07-2009, 08:36 PM   #6
Wright Guard
 
phreebsd's Avatar
 

Join Date: Dec 2004
Location: Bama
Posts: 6,753
Images: 37
phreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to all
true dat.

Instructions modified.








__________________________
2008 Kawasaki Teryx
31" Laws
Black ITP SS212's
Relocated Radiator
Maroon Primary
Yellow Secondary
MIMB Snorkels (dual 2" intake)
Rejetted
RaceDriven Sintered Metal Brake Pads
BigGun EVO Exhaust
Viper Max 5000 WideSpool with Amsteel Blue

TEAM ROLLIN' DEEP 2013

2008 Yamaha WR250R
phreebsd is offline  
Feedback: (7)
Reply With Quote Go to top
Old 04-28-2009, 07:48 PM   #7
Trail Rider
 

Join Date: Mar 2009
Location: Jackson, MS
Posts: 86
mississippimud3 is on a distinguished road
thanks for the writeup will be using that in a couple of weeks. Will be relocating the radiator before the Marengo Swamp Ride.








__________________________
09 Dark Red 750 Brute Force
2 inch HL Lift / HL Springs
HL Outlaw extreme duty clutch Kit
31 Laws on 212 Chrome
Upgraded tie rods with All Balls Ends
Full Muzzy Exhaust
MIMB Snorkels
Custom Split Audiopipe
Radiator Relocated
PCIII
mississippimud3 is offline  
Feedback: (0)
Reply With Quote Go to top
Old 04-28-2009, 09:30 PM   #8
Trail Rider
 
mudboots's Avatar
 

Join Date: Apr 2009
Location: texas
Posts: 43
mudboots is on a distinguished road
yes,that was another great how to only thing i did different was use 3/16" plate for the base. Easy and saved alot of money, Looks and works great








__________________________
750 Brute Force
28"skinnys /Laws
s/s 212 black
2''HL lift
MIMB snorks
Rad. lifted
HMF
Optimizer/3
Green secondary
mudboots is offline  
Feedback: (0)
Reply With Quote Go to top
Old 04-28-2009, 10:05 PM   #9
Wright Guard
 
phreebsd's Avatar
 

Join Date: Dec 2004
Location: Bama
Posts: 6,753
Images: 37
phreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to all
Quote:
Originally Posted by mississippimud3 View Post
thanks for the writeup will be using that in a couple of weeks. Will be relocating the radiator before the Marengo Swamp Ride.
From what i have seen of marengo on youtube a relocated radiator is a must!
Man yer gonna have a good time!








__________________________
2008 Kawasaki Teryx
31" Laws
Black ITP SS212's
Relocated Radiator
Maroon Primary
Yellow Secondary
MIMB Snorkels (dual 2" intake)
Rejetted
RaceDriven Sintered Metal Brake Pads
BigGun EVO Exhaust
Viper Max 5000 WideSpool with Amsteel Blue

TEAM ROLLIN' DEEP 2013

2008 Yamaha WR250R
phreebsd is offline  
Feedback: (7)
Reply With Quote Go to top
Old 04-30-2009, 10:35 AM   #10
Newbie
 
outlaw brute08's Avatar
 

Join Date: Mar 2009
Location: Vicksburg, MS
Posts: 28
outlaw brute08 is on a distinguished road
Great write up....will be using this soon








__________________________
2009 BF 750i
HL Springs
2" Extreme lift
Warn 2500
29.5" Laws
ITP SS212's
EPI Red secondary
M.I.M.B. center snorkels
MORE TO COME!!!
outlaw brute08 is offline  
Feedback: (0)
Reply With Quote Go to top
Old 04-30-2009, 11:42 AM   #11
Wright Guard
 
phreebsd's Avatar
 

Join Date: Dec 2004
Location: Bama
Posts: 6,753
Images: 37
phreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to all
thanks!








__________________________
2008 Kawasaki Teryx
31" Laws
Black ITP SS212's
Relocated Radiator
Maroon Primary
Yellow Secondary
MIMB Snorkels (dual 2" intake)
Rejetted
RaceDriven Sintered Metal Brake Pads
BigGun EVO Exhaust
Viper Max 5000 WideSpool with Amsteel Blue

TEAM ROLLIN' DEEP 2013

2008 Yamaha WR250R
phreebsd is offline  
Feedback: (7)
Reply With Quote Go to top
Old 05-01-2009, 09:06 PM   #12
SAY I WON'T!!!
 
DrillersGoDeeper's Avatar
 

Join Date: Jan 2009
Location: Jonesboro, LA
Posts: 997
DrillersGoDeeper will become famous soon enough
Great write up! Lots of people doing this now. Much needed upgrade for the Brutes!!!








__________________________
Dale Golden

SUPPORT OUR TROOPS

2009 CAN AM 800R OUTTYMAX
SS212/28" SILVERBACKS
MUD INDUSTRIES SNORKELS
RUBBERDOWN CUSTOM POW/MIA RAD RELOCATE

2012 Can Am Commander 1000 XT
29.5 HL Outlaw2's
CVTech Primary & machined secondary
Custom Diamond Plate roof/BRP half windshield
Rigid 10" SR LED light bar/42" light bar
Yeti Cooler for the Cold Beers!
DrillersGoDeeper is offline  
Feedback: (0)
Reply With Quote Go to top
Old 05-02-2009, 05:12 PM   #13
Newbie
 
rhettag94's Avatar
 

Join Date: Apr 2009
Location: Tyler, TX
Posts: 24
Images: 4
rhettag94 is on a distinguished road
Thanks. I did mine last night. Those two 8mm bolts were a pain. I have big hands and that took the longest to do.








__________________________
2007 BRUTE 650I CAMO 14 IN SS 108 BLACK
27 ITP XTR MUDLITES, MIMB SNORKELS
1 1/2 HL WHEEL SPACERS, H/L SPINGS AND 2 INCH LIFT, PENLOCK, CRANK CASE MOD
MAROON PRIMARY ALMOND SECONDARY, MOOSE POWER MODULE, FUEL CELL CARRIER MOD
UNI FILTER OUTERWEAR PRE FILTER
MIMB EXHAUST MOD, RAD RELOCATE
2007 HONDA RINCON
ONE HOT LADY
rhettag94 is offline  
Feedback: (0)
Reply With Quote Go to top
Old 05-02-2009, 05:15 PM   #14
Gettin Muddy
 
muddnfool's Avatar
 

Join Date: Mar 2009
Location: Tyler,Texas
Posts: 226
muddnfool is on a distinguished road
Send a message via AIM to muddnfool
hey rhett can get some pics on here of yours








__________________________
05 Brute Force 750
HMF exhaust
Maroon Primary
Green Secondary
Austin Garner Special Snorks.
Moose Module
UNI Air Filter
HL 2 inch lift
27 589's (bout to get some crushed backs)
muddnfool is offline  
Feedback: (0)
Reply With Quote Go to top
Old 05-02-2009, 10:20 PM   #15
Professional Mudder
 
Yesterday's Avatar
 

Join Date: Jan 2009
Location: Central Arkansas
Posts: 1,435
Images: 15
Yesterday is on a distinguished road
yeah that radiator shroud gets in the way bad =/
Yesterday is offline  
Feedback: (0)
Reply With Quote Go to top
Old 05-05-2009, 03:55 PM   #16
Experienced Mudder
 
meangreen360's Avatar
 

Join Date: May 2009
Location: Huffman,tx
Posts: 534
meangreen360 is on a distinguished road
Drilled the hole 9/32 and the 6mm tap is to small. Am I suppose to use a 8mm tap? The write up says to use a 6mm tap.








__________________________
08 Brute 750i
7'' Highlifter lift-monkey axles- hl springs
1.5 spacers-ss112 wheels-31 laws
rad uptop-mimb snorks-cooler rack
hid's-oil cooler-full muzzy
pc3-ignition module-green led display
temp gauge-xtx belt-epi clutch kit
meangreen360 is offline  
Feedback: (0)
Reply With Quote Go to top
Old 05-05-2009, 07:39 PM   #17
Professional Mudder
 
Yesterday's Avatar
 

Join Date: Jan 2009
Location: Central Arkansas
Posts: 1,435
Images: 15
Yesterday is on a distinguished road
that's only if you wish to reuse the stock mounting bolt. you can make it easy and drill a bigger hole and use a bolt/nut and not have to worry about tappin it
Yesterday is offline  
Feedback: (0)
Reply With Quote Go to top
Old 05-05-2009, 08:11 PM   #18
Wright Guard
 
phreebsd's Avatar
 

Join Date: Dec 2004
Location: Bama
Posts: 6,753
Images: 37
phreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to all
I will double check. I bet the drill bit size is wrong. I hollered across the shop asking what size it was while i was tapping the first hole and he was drilling the second one.








__________________________
2008 Kawasaki Teryx
31" Laws
Black ITP SS212's
Relocated Radiator
Maroon Primary
Yellow Secondary
MIMB Snorkels (dual 2" intake)
Rejetted
RaceDriven Sintered Metal Brake Pads
BigGun EVO Exhaust
Viper Max 5000 WideSpool with Amsteel Blue

TEAM ROLLIN' DEEP 2013

2008 Yamaha WR250R
phreebsd is offline  
Feedback: (7)
Reply With Quote Go to top
Old 05-05-2009, 08:48 PM   #19
Wright Guard
 
phreebsd's Avatar
 

Join Date: Dec 2004
Location: Bama
Posts: 6,753
Images: 37
phreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to allphreebsd is a name known to all
ok i double checked.
the bit is a 7/32 not 9/32. if u want to tap the 9/32 hole u drilled an 8mm tap fits that hole.

sorry for the typo. i corrected the information in the how-to.








__________________________
2008 Kawasaki Teryx
31" Laws
Black ITP SS212's
Relocated Radiator
Maroon Primary
Yellow Secondary
MIMB Snorkels (dual 2" intake)
Rejetted
RaceDriven Sintered Metal Brake Pads
BigGun EVO Exhaust
Viper Max 5000 WideSpool with Amsteel Blue

TEAM ROLLIN' DEEP 2013

2008 Yamaha WR250R
phreebsd is offline  
Feedback: (7)
Reply With Quote Go to top
Old 05-06-2009, 06:05 AM   #20
Experienced Mudder
 
meangreen360's Avatar
 

Join Date: May 2009
Location: Huffman,tx
Posts: 534
meangreen360 is on a distinguished road
No big deal. I used a number 9 drill bit. Then tap it out with 6mm. The write up is awsome and is a must for a brute.








__________________________
08 Brute 750i
7'' Highlifter lift-monkey axles- hl springs
1.5 spacers-ss112 wheels-31 laws
rad uptop-mimb snorks-cooler rack
hid's-oil cooler-full muzzy
pc3-ignition module-green led display
temp gauge-xtx belt-epi clutch kit
meangreen360 is offline  
Feedback: (0)
Reply With Quote Go to top
Reply

Bookmarks


Search tags for this page
05 brute force radiator relocator kit materials needed
,
2005 brute force 750 radiator relocation
,
brute force 750 radiator relocation
,
brute force 750 radiator relocation kit
,

brute force radiator relocation

,
brute force radiator relocation kit
,
how to make brute force rad relocate
,
how to relocate radiator on brute force
,
how to relocate radiator on kawaskai brute
,
what size radiator hose is on a 07 kawasaki brute 750
Click on a term to search for related topics.

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
HELP!!! Radiator Relocate q's OCCKawi Kawasaki 3 06-11-2012 04:09 AM
Polaris radiator relocate IBBruin Polaris 20 10-02-2011 07:39 AM
Teryx radiator relocate Outlaw SxS Playground 5 07-11-2010 02:56 PM
Here is whatever one wanted, pictures!!!! - Radiator Relocate mississippimud3 Kawasaki 12 05-26-2009 03:40 PM
Radiator Relocate DONE!! mississippimud3 Kawasaki 7 05-25-2009 01:41 PM


All times are GMT -6. The time now is 03:35 AM.


Powered by The Mighty Kawasaki V-Twin
MudInMyBlood 2006-2011
BFWDP

SEO by vBSEO ©2011, Crawlability, Inc.