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Cr500 tunnel cooler

wwillf01

Well-known member
Lifetime Membership
It sounds like a few people have gone the tunnel cooler route on the cr500? If so how is the flow working and what cooler fit the best?

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I run a kx500 with a tunnel cooler I modified to fit right above the drivers, it is only 8"x9". I am running the KTM thermostat and took out both rads, and I have been running 160 pretty consistently, with no engine shrouds. the highest I have seen is 186 so far since mid feb when I did the swap. That is all in minimal snow as well
 
I run a kx500 with a tunnel cooler I modified to fit right above the drivers, it is only 8"x9". I am running the KTM thermostat and took out both rads, and I have been running 160 pretty consistently, with no engine shrouds. the highest I have seen is 186 so far since mid feb when I did the swap. That is all in minimal snow as well

What year kit do you have?

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I am running a TKS snowbike, not comparable to the TS but, in terms of whats the right size, I feel 8x9 is on the small side but it is still doable
 
Mine was a old indy cooler, the one that would go up in front of the tunnel, I ended cutting it in half from and using the side that had the tubes sticking up for the rad hoses. pretty easy to weld the end shut too.
 
Now how are people routing the coolant lines back to the cooler... Just attached to the side?


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This is on reason i like the pre 15 kits. The cooler works better hose routing wise. As far as routing of the hoses pretty simple. From the head to Thermobob to cooler to top of right rad. I'd run the bypass from Thermobob to the bottom of the right rad (either into a rad fitting or Thermobob T). I'd personally nix the left rad. If you run carb heat id T it back into cooler return or bottom of right rad. Simple.

Ravenous has a great setup on a KX500. Prob one of the best stable temp 500s I've kinda seen. The cooler is the way to solve up the trail heat issues on the 500. In the deep a stat is not needed imo but with the cooler you would end up using one. Thermobob has a 130F stat for the 2 stroke guys. It has the bypass and also a probe port if you were wondering. Bill is a super nice guy and can help you. He has a lot of great data on temps etc.
 
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I was going just ice scratchers and mixing Both radiators ... Then I am going to have to run the hoses on the side of the tunnel


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Ya it kinda sucks that TS did the tunnel the way they did for 15/16. We threw the idea of running a cooler in the spine but not sure if it will get enough snow there. The hoses would be cleaner for sure.
 
Ya it kinda sucks that TS did the tunnel the way they did for 15/16. We threw the idea of running a cooler in the spine but not sure if it will get enough snow there. The hoses would be cleaner for sure.


More worried about them catching on stuff then the look at this point.. So I was going to encase them in some type of plastic tubing so they are less likely to catch and a little more puncture resistant.. I think that is best case scenario.... The cooling issue is my last hurdle .....


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This is what I am thinking of using to protect the exposed hoses
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Racking my brain not enough clearance under... I can't loose the fuel carrier because I need the fuel... I could go to rails for fuel on the rear .. Maybe I will look for a different way to carry fuel that said I am going to try to shim the carrier so I can fit the lines under we will see how that works with tss


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What about building a floor under the fuel can maybe raise it a inch ? Not sure what do do.
 
That was the though with a shim then I think I will have to trim the rear fender


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oh duh i forgot, it would not be hard to make a bracket that moves the can back 3 inches. edit: it actually took 5 inches back on mine
 
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tunnel cooler

im confused on this tunnel cooler...I have a 2012 kx500af timbersled and I don't see the need to add additional cooling for these things. there is no additional cooling for the trails with dirt tires in the middle of summer when its 90deg out so why would it need it in winter with all the cool air rushing past the motor/radiators? ive only had antifreeze boil over once and that was a long slow 4 min climb going slow
 
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