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I replace my OEM radiator with the InoKinetic ChampRad as a preventative measure this weekend and thought I would pass along a few tips that may help others.

http://www.lotustalk.com/forums/attachment.php?attachmentid=1201474

Some of the OEM bolts are a PITA to get out due to very limited access for a ratchet or wrenches. The most troublesome for me were the four 8mm bolts at the top of the radiator that mount to the fan frame and the two 10 mm nuts hidden under the air cowling that are possibly accessible via the front grill area.
Since I didn’t have any offset wrenches that would allow me to remove the nuts under the cowling, I decided to do some surgery and add some lightness. I located the nuts and estimated the location on the cowling and used a 1 ¼ inch diameter forstner bit to make a hole that would allow a wrench to easily get to the nut on the stud. I drilled it twice to form a vertical slot which helped with access and getting the nut off. These slots also help in allowing a way for pushing the radiator up onto the fan bracket at the stud locations.

http://www.lotustalk.com/forums/attachment.php?attachmentid=1201482

http://www.lotustalk.com/forums/attachment.php?attachmentid=1201490
 

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Premium Member
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77 Posts
Discussion Starter #2
The ChampRad is a nicely made radiator and as expected was a drop-in replacement for the original. It had slots to help with reinstallation onto the two studs under the cowling. The one modification I made to it was to enlarge the holes on the top part of the mounting bracket so I could get a socket on the 8mm bolts and not have to mess with the wrenches for reinstallation. I enlarged the 4 holes to ½ inch diameter which allowed enough clearance for a tall socket. I also replaced the OEM nuts used under the bracket for the 8mm bolts with some clips that have captured nuts. This made installing the 8mm bolts a lot easier.

http://www.lotustalk.com/forums/attachment.php?attachmentid=1201498

http://www.lotustalk.com/forums/attachment.php?attachmentid=1201506

http://www.lotustalk.com/forums/attachment.php?attachmentid=1201514

http://www.lotustalk.com/forums/attachment.php?attachmentid=1201522
 

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