Radiator Removal

[Freebird]

How to Remove Your 2nd Gen Radiator

Well let me start off by saying 14 months ago I had a little Mishap,

http://www.venturerider.org/forum/showthread.php?t=2437&highlight=Radiator+Leak

I had to remove my Radiator and I decided to have it welded. Seems that part
Held up ok... but now I have another leak, so here go’s

Also, I had to use my Daughters Dig Camera and the pictures are not that great
But I hope this helps someone if needed. (Note: all left and right are
As if I was sitting on the bike)

# 1 Remove the two bolts on the left and right lower fairings (# 4 mm Allen Wrench)

#2 Look way under the bottom in the middle of the two lower fairings there will be
A black plastic screw that helps hold the lower fairings together... the black bolt goes into this hole.

http://www.venturerider.org/forum/../radiator/pic1.jpg

#3 now remove the one bolt on the other sides near your air filters

http://www.venturerider.org/forum/../radiator/pic2.jpg

#4 here is a critical part in removing the two half’s. Make sure you
Remove the RIGHT Lower fairing first, or you will most likely break on of these tabs, if you do JB Weld holds them back
In place just fine. I know this because I broke on last year!

http://www.venturerider.org/forum/../radiator/pic3.jpg

This is how the two half’s look a bit apart left/right

http://www.venturerider.org/forum/../radiator/pic4.jpg

#5 remove the white plastic hose holder down under at the bottom of the lower fairings.

http://www.venturerider.org/forum/../radiator/pic5.jpg

#6 Now remove the black power wire on the left side for the fan
this will be located on the left side.

http://www.venturerider.org/forum/../radiator/pic6.jpg


#7 Now remove the drain plug and drain the antifreeze.

http://www.venturerider.org/forum/../radiator/pic7.jpg
http://www.venturerider.org/forum/../radiator/pic8.jpg

#8 Now the FUN part… loosen the top clamp for the rad hose.

http://www.venturerider.org/forum/../radiator/pic9.jpg

And next the lower clamp, I did notice the first time I loosened
The clap after the factory had placed them they were very hard
To get to.. Now I placed them so I can remove them in the future
If needed.

#9 The Bottom hose MUST be removed first, stick a screwdriver
Or whatever in base of the hose to loosen it a bit. Do not tear the hose. Just deal with it and it will come loose sooner or later.

http://www.venturerider.org/forum/../radiator/pic10.jpg

#10 now work on removing that top hose in the same manner,
As it starts to come loose you will be removing the Rad with
A pulling downward motion and also remove it from the top TAB
HOLDER.

http://www.venturerider.org/forum/../radiator/pic11.jpg
http://www.venturerider.org/forum/../radiator/pic12.jpg

#11 Now with the RAD kind of hanging in place make sure you
might want to put a towel on the rear of the front fender
as well.. DISCONNET the Orange Plug from the Temp
Censer. Squeeze the top/rear and it will pull right off.

http://www.venturerider.org/forum/../radiator/pic13.jpg

Now you have removed the Radiator.

Here are some shoots not very good but what to
Remove from the Rad before having it Welded
Or Adding the Rad Parts back onto a new one
Like I just ordered.. I will have this one checked
And re-welded for a back-up in the future maybe.

http://www.venturerider.org/forum/../radiator/pic14.jpg
http://www.venturerider.org/forum/../radiator/pic15.jpg
http://www.venturerider.org/forum/../radiator/pic16.jpg
http://www.venturerider.org/forum/../radiator/pic17.jpg
http://www.venturerider.org/forum/../radiator/pic18.jpg
http://www.venturerider.org/forum/../radiator/pic19.jpg
http://www.venturerider.org/forum/../radiator/pic20.jpg
http://www.venturerider.org/forum/../radiator/pic21.jpg

Here are some pics of how my old one looks now and the old
Weld, looks like it help up.. I also have ordered a NEW RADITATOR Cover from Steve. To match my MM Venture.
So maybe this will my love of removing 2nd Gen Radiators?
http://www.wagnercustomproducts.com/
Should look very kewl!

http://www.venturerider.org/forum/../radiator/pic22.jpg
http://www.venturerider.org/forum/../radiator/pic23.jpg
I hope nobody has to go through this ever!
And if So I hope this helps you a bit.
Feel free to PM me if you need to contact
Me about this project if you ever have to do this. Thanks again Scotty.

Jeff