Using KX500 radiators on the 99-02 KX250 frame

[sintax]

Has anyone used the 500 radiators? I'm thinking there may be some headache getting everything to look good. It appears as if the 250 radiators are shorter then the 500 units. I dont have a set off a 250 to compare to though.

[don46]

I use the K5 radiators exclusively on all the hybrids I've done. Can't remember the size of the left 250 radiator but there are some clearance issues and the 500 radiator minimizes them, although I've never tried the 250 radiators so I couldn't say, the 500 radiators work fine no issues, just have to move the mounting brackets.

[sintax]

Excellent news Don.

I'll try that first then.

When you say moving the brackets, I know that means the frame side ones, but what about the ones that the shrouds mount to. I'm assuming those would have to be relocated as well.

Not a huge problem. I got a buddy who welds aluminum.

[don46]

Only the bottom mount goes to the radiator, on the right side it takes a spacer and the left I welded a small block and tapped it to align with the shroud

[BDI]

The 250 rads were a touch bigger then the 500 rads if I remember right. I moved the lower rad mount forward 6mm and cleaned off a weld seem on the frame so the lower cross over tube/hose would fit between the frame and the cylinder. The left radiator hose that goes from the rad to the head is actually the 250 hose that went from the water pump to the rad. It went on with zero mods. The right hand hose that goes from the pump to the rad is the stock kx500 hose with a couple of inches cut off.  All the plastics line up perfect and no other mods were necessary. On a scale of 1 to 10 of difficulty I would call it a 2 And thats if you happen to spill your beer while doing it. I have no idea how hard the 500 rad swap is because I never even tried it. Don you got any picture of that

[JBKX]

How did your rad. shrouds fit after moving the bottoms 6mm?  Did you slot the holes in the shrouds?  Thanks for the pics.

[BDI]

How did your rad. shrouds fit after moving the bottoms 6mm?  Did you slot the holes in the shrouds?  Thanks for the pics.

               No the shrouds bolt right up with no moding. Because you are only moving the rad by the frame and the outer mount stays the same and so does the shroud mounting hole.

[JBKX]

Thanks, I'll give it a try!!!

[kawiscooter]

Has anyone doing this conversion has issues using the stock KX250 radiators? I'd like to use them if I can because my K5 donor has hammered radiators but the 2002 KX250 are like new.

What do ya'll think, will the stock 250 rads keep the K5 motor cool?

Thanks in advance!

[BDI]

I'm using them and they work perfectly. I myself would only do it with the 250 rads or a custom one off set with some sweet tig welded tank's.