Rubberdown
06-19-2011, 10:06 PM
http://i79.photobucket.com/albums/j158/rubberdown/Rad%20Relocation%20Kits/bruteforceradkit1.jpg
Make sure to clean your ATV very well, this makes for a much easier job.
With a drain pan below the ATV, remove the stock hoses from stock radiator and drain the Antifreeze and unplug the fan. Removing the front rack and/or other plastic shrouds might make this an easier job.
Un-bolt and remove the radiator from the machine, keep in mind that this is the BEST time to clean your radiator and get all the deep packed in mud cleaned out for best cooling before remounting. Air Conditioner cleaner or aluminum rim cleaner works great to really break up the dirt and get it looking good again.
Assemble the new RDC Rad Bracket with the 3/4” long carriage bolts. Install the radiator into the bracket. Now place the bracket with the radiator mounted inside it on the front rack so the supplied U-Bolts and mounting holes will line up on the front rack cross bars and loosely bolt it in place.
You will need to cut the end off of one of the stock hoses, one of them will have roughly a 90 degree formed bend, you need to cut this off as pictured below,
http://i79.photobucket.com/albums/j158/rubberdown/Rad%20Relocation%20Kits/PA193268.jpg
This little piece of stock rubber hose needs to be attached to the lower radiator orifice as pictured below, this allows for a nice smooth flow of coolant and an easier fit
http://i79.photobucket.com/albums/j158/rubberdown/Rad%20Relocation%20Kits/PA193269.jpg
Figure out where you want your hose holes in the front of the ATV, I ran all of the hoses through the center plastic piece and center snorks were added afterwords so both WILL fit.
Use the supplied hose, barbs and hose clamps to reconnect the stock hoses to the radiator in the new RDC Bracket. Make sure there are no kinks in the original or new hoses, in some cases cutting back the stock hoses will work better
The fan wires will need to be extended, cut the wires and splice in 12" of wire to both of the stock wires. The supplied connectors are heat shrink connectors, once you crimp them, you can heat shrink them with a heat gun or lighter.
There is a clear length of hose for the overflow bottle, this runs to the nipple on the fill neck, this will replace the stock overflow hose.
Once everything is tight you can refill the radiator.
Burping the radiator may be required to ensure proper cycling of the coolant. This can be done by letting the ATV idle with the radiator cap off, and massaging the radiator hoses to try and work out any air blockages, once all the air bubbles have come out of the radiator cap, re-fill and you are ready to go. Be sure to check on your coolant level before and after each ride to make sure it was completely burped and free of air blockages.
http://i79.photobucket.com/albums/j158/rubberdown/Rad%20Relocation%20Kits/PA203283-1.jpg
Make sure to clean your ATV very well, this makes for a much easier job.
With a drain pan below the ATV, remove the stock hoses from stock radiator and drain the Antifreeze and unplug the fan. Removing the front rack and/or other plastic shrouds might make this an easier job.
Un-bolt and remove the radiator from the machine, keep in mind that this is the BEST time to clean your radiator and get all the deep packed in mud cleaned out for best cooling before remounting. Air Conditioner cleaner or aluminum rim cleaner works great to really break up the dirt and get it looking good again.
Assemble the new RDC Rad Bracket with the 3/4” long carriage bolts. Install the radiator into the bracket. Now place the bracket with the radiator mounted inside it on the front rack so the supplied U-Bolts and mounting holes will line up on the front rack cross bars and loosely bolt it in place.
You will need to cut the end off of one of the stock hoses, one of them will have roughly a 90 degree formed bend, you need to cut this off as pictured below,
http://i79.photobucket.com/albums/j158/rubberdown/Rad%20Relocation%20Kits/PA193268.jpg
This little piece of stock rubber hose needs to be attached to the lower radiator orifice as pictured below, this allows for a nice smooth flow of coolant and an easier fit
http://i79.photobucket.com/albums/j158/rubberdown/Rad%20Relocation%20Kits/PA193269.jpg
Figure out where you want your hose holes in the front of the ATV, I ran all of the hoses through the center plastic piece and center snorks were added afterwords so both WILL fit.
Use the supplied hose, barbs and hose clamps to reconnect the stock hoses to the radiator in the new RDC Bracket. Make sure there are no kinks in the original or new hoses, in some cases cutting back the stock hoses will work better
The fan wires will need to be extended, cut the wires and splice in 12" of wire to both of the stock wires. The supplied connectors are heat shrink connectors, once you crimp them, you can heat shrink them with a heat gun or lighter.
There is a clear length of hose for the overflow bottle, this runs to the nipple on the fill neck, this will replace the stock overflow hose.
Once everything is tight you can refill the radiator.
Burping the radiator may be required to ensure proper cycling of the coolant. This can be done by letting the ATV idle with the radiator cap off, and massaging the radiator hoses to try and work out any air blockages, once all the air bubbles have come out of the radiator cap, re-fill and you are ready to go. Be sure to check on your coolant level before and after each ride to make sure it was completely burped and free of air blockages.
http://i79.photobucket.com/albums/j158/rubberdown/Rad%20Relocation%20Kits/PA203283-1.jpg