James
Staff member
500 KX500 PF
- Thread starter cutting torch
- Start date
Now for the cooling of the beast.....
The 500 has a series cooling circuit, and the 250 is a parallel cooling circuit. I need to use the 250 system since it fits the chassis (just like stock!
). I'll describe how each system flows, starting at the water pump inlet.
500:
Water pump inlet, to wp outlet, to right side of jug, up through jug to head, out of head on the left side, to bottom of left rad, from top of left rad to top of right rad, from bottom of right rad back to the water pump inlet. This circuit is in series since the coolant flows through one radiator, then flows through the other.
250:
Water pump inlet, to wp outlet, to rear side of jug, up through jug to head, out of head on the top rear WITH TWO OUTLETS going to the top of each rad, through both rads to the bottom of both rads, and back to the water pump inlet. This is parallel since the coolant flows through both radiators at the same time.
Just in case anyone thinks I am belittling them by spelling out the differences between series and parallel, remember that there are some people that just never knew this. It's for thier benefit. So
.
Next post has pics!
torch
The 500 has a series cooling circuit, and the 250 is a parallel cooling circuit. I need to use the 250 system since it fits the chassis (just like stock!
). I'll describe how each system flows, starting at the water pump inlet.500:
Water pump inlet, to wp outlet, to right side of jug, up through jug to head, out of head on the left side, to bottom of left rad, from top of left rad to top of right rad, from bottom of right rad back to the water pump inlet. This circuit is in series since the coolant flows through one radiator, then flows through the other.
250:
Water pump inlet, to wp outlet, to rear side of jug, up through jug to head, out of head on the top rear WITH TWO OUTLETS going to the top of each rad, through both rads to the bottom of both rads, and back to the water pump inlet. This is parallel since the coolant flows through both radiators at the same time.
Just in case anyone thinks I am belittling them by spelling out the differences between series and parallel, remember that there are some people that just never knew this. It's for thier benefit. So
.Next post has pics!
torch
Pics! Whoooo!
The water pump inlet manifold from the 250 is wider than the 500, from bolt-to-bolt....
So, I welded up the holes to relocate them:
Then, I milled and drilled: Note: KX500 heads seem to be a purer alloy than KX250 water manifolds, based on the way they weld. I need to fix these pits:
In order to move the bolt holes in, I needed a smaller bolt head. Hello, Allen!
The factory bolt was too fat:
Here are pics of how things will lay out. I still need to make a wye to split the coolant between the radiators for the parallel arangement I want. That wye will split the coolant flow in half between the head and the top of each radiator.
torch
The water pump inlet manifold from the 250 is wider than the 500, from bolt-to-bolt....
So, I welded up the holes to relocate them:
Then, I milled and drilled: Note: KX500 heads seem to be a purer alloy than KX250 water manifolds, based on the way they weld. I need to fix these pits:
In order to move the bolt holes in, I needed a smaller bolt head. Hello, Allen!
The factory bolt was too fat:
Here are pics of how things will lay out. I still need to make a wye to split the coolant between the radiators for the parallel arangement I want. That wye will split the coolant flow in half between the head and the top of each radiator.
torch
Just awesome CT - the pics really make this build come alive.
Bet you cant wait to start riding that monster. 
Nice, everything is looking good. It's really cool seeing how you do these things
Nice, everything is looking good. It's really cool seeing how you do these things
Thank you!
I have no plans to build this bike for anyone other than myself, so I don't need to keep anything secret. I want my ideas to help people that want to do a similar build.
torch
It's got a skidplate that I will modify if needed to protect everything. It'll get othe armor as well.
torch
torch
too bad this hasn't been updated since June 18th by the OP. I wander what happen? Calling out to torch we need an update!!!!!!
I agree!