Chinese/GPI rad install KX500

Burle
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Joined: Thu Oct 20, 2016 9:47 am

Chinese/GPI rad install KX500

Post by Burle » Wed Mar 04, 2020 1:33 am

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.
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Left side had two holes that lined up well
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Right side could only make one hole work so I chose the on that made the rad shroud plastic holes line up best
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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
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I did the exact same thing for the bottom mount on the right side rad
Last edited by Burle on Wed Mar 04, 2020 3:53 am, edited 2 times in total.

Burle
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Joined: Thu Oct 20, 2016 9:47 am

Re: Chinese/GPI rad install KX500

Post by Burle » Wed Mar 04, 2020 1:39 am

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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
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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

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Sandblaster
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Re: Chinese/GPI rad install KX500

Post by Sandblaster » Wed Mar 04, 2020 4:44 am

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 :D
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
If bikes are for kids I'll never grow up.

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Sandblaster
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Re: Chinese/GPI rad install KX500

Post by Sandblaster » Wed Mar 04, 2020 5:34 am

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


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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.
If bikes are for kids I'll never grow up.

Burle
Posts: 40
Joined: Thu Oct 20, 2016 9:47 am

Re: Chinese/GPI rad install KX500

Post by Burle » Wed Mar 04, 2020 2:27 pm

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.

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Sandblaster
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Re: Chinese/GPI rad install KX500

Post by Sandblaster » Wed Mar 04, 2020 3:41 pm

Excellent!
Start a new thread under Bike Builds and take lots of pics 8-)
If bikes are for kids I'll never grow up.

Burle
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Joined: Thu Oct 20, 2016 9:47 am

Re: Chinese/GPI rad install KX500

Post by Burle » Sat Apr 04, 2020 2:55 pm

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
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Re: Chinese/GPI rad install KX500

Post by Burle » Sat Apr 04, 2020 3:07 pm

Tig welded on some mount braces, hopefully won't have to deal with cracks in the future
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Burle
Posts: 40
Joined: Thu Oct 20, 2016 9:47 am

Re: Chinese/GPI rad install KX500

Post by Burle » Sat Apr 04, 2020 3:12 pm

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
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Had some contamination issues with the weld, aluminum is hard, I have faith it'll seal though
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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
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Re: Chinese/GPI rad install KX500

Post by Burle » Sat Apr 04, 2020 3:22 pm

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The aluminum where the rad shrouds mount was too thick for the little nut clips
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Just shaved them down a bit
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