• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

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    Thanks for your patience and support!

Different Radiator for TE630 possibly TE/TC250

N

NVR2L8

Husqvarna
AA Class
OK as most of you know I've had regular problems with my radiators on my TE630. 3 failures in the last 7 months. So this time after reading here abpout a possible replacement radiator fro the TC/TE 250 I went ahead an bought an after market TE/TC 250 radiator.

Everything appeared to be in the exact same place but when I went to install it I ran into a couple minor problems.

The 250 radiators are quite a bit thicker than the 630 OEM radiators which led to the first issue, the new radiators push back against the radiator hoses where they T off on the vlave cover. Now I don't think the radiators will get hot enough to melt the hoses but maybe someone will provide their thoughts on this. I would run it and see but there is another problem.

The radiator fan mounting bracket doesn't quite line up so I'm thinking I'll have a new one fabricated up. right now I can get the top outer bolt in but the inside mount where the long bolt attaches and stabilizes the two radiators doesn't quite line up and neither does the lower bolt holes.

Even with the new fan bracket it is going to be pretty tight spacing wise. any thoughts are appreciated.

Just FYI these are aftermarket radiators and look pretty stout hopfully if I can get them mounted up they will perform better than the OEM.
 
Just a thought, if the coolant in the hoses doesn't melt them, the radiator, which is heated by that coolant, shouldn't melt them... :P
 
In cases like that I have sometimes cut a sleeve of other old rad hose and put it around the hose at the spot. Not for heat but to prevent rubbing wear on the hose. Cam.
 
I had the hose issue when i fitted mine too, i just pushed them a little further toward the spark plug so they weren't as squished.
As for the fan, i used 7602 braces which have a different mount which makes the fan sit quite nicely
 
Went to a fabrication place today, they wanted 75.00 an hours to make a new bracket and about 1.5 hours labor so it would be over 100.00 think I would go with the 7602s before I did that. I was thinking about the OEM 250 fan mount but not sure if the 630 fan would mount up to it. The fan part number for the 630 and 250 are the same the mounting bracket is of course different, but it should make things fit correctly?. Any knowledge here would be appreciated.

Maxyb what model 7602's did you use and just to confirm you mounted the 250 radiators on your 630.

I may just try to fab it up myself but with out a sheet metal break it will be difficult. Again any ideas area appreciated.
 
NVR2L8 said:
Maxyb what model 7602's did you use and just to confirm you mounted the 250 radiators on your 630.
Click to expand...

I bought the braces 7602 make for the 630; just checked their site, they don't have them up there anymore :confused: (possibly contact them?)


and yes, i have aftermarket chinese welded tanks from the 2010-2011 te250 - ebay cheapies with the same orientated outlets as the 630 has


you can see here that you don't need the stock fan bracket, they bolt straight to the braces. The only problem with this is it moves it down a few mm, squishing the hose, all you do is pull the hose out from being squished.
when bolting on the fan take note of which direction the wire is pointing too.

 
Good deal that looks like the ticket, I put a call into them hopefully they still make the 630 model. Thanks for the info.

I've tried to think of something i could use as a break but so far no bueno.
 
I put the 7602 braces on my 630. The kit they sell is for the 610 and it fits okay. I had them exchange the right side guard (on the 610 that is were the tank is) with another for the left so you get full coverage on the rad. The fan I had to mount lower and rotate to get to fit with out crushing the hoses and hit the back of the fuel tank. The front fender will hit the guards and frames so I rounded off the lower inside corners to clear, also added a couple of washer at the back of the fender mount to space it away from the rad braces. These were certainly not a direct bolt on, but can be made too work. Luckily he had a deal going when I ordered so that compensated for some of the hassles involved.
 
I put the 7602 braces on my 630. The kit they sell is for the 610 and it fits okay. I had them exchange the right side guard (on the 610 that is were the tank is) with another for the left so you get full coverage on the rad. The fan I had to mount lower and rotate to get to fit with out crushing the hoses and hit the back of the fuel tank. The front fender will hit the guards and frames so I rounded off the lower inside corners to clear, also added a couple of washer at the back of the fender mount to space it away from the rad braces. These were certainly not a direct bolt on, but can be made too work. Luckily he had a deal going when I ordered so that compensated for some of the hassles involved.
 
Good deal that looks like the ticket, I put a call into them hopefully they still make the 630 model. Thanks for the info.
Click to expand...

We removed the radiator braces and guards from our 630 page. As mentioned above, the 630 uses a thinner radiator than the other husky models and this was leading to problems with the rad hoses not having enough room behind the radiator braces. I'm not sure why there is such a variance from one bike to the next, but it seems that some customers have minimal fitment issues, while others simply can't make them fit.

With the 630 out of production and likely not coming back we have no plans to revise our design and make another run of braces for the 630's.
 
OK well status report. I fabricated a mount for the fan myself, it was pretty easy looks like hell but you can't really see it, I'll paint it on another day. The TE 250 radiator I got are a pretty tight fit but they fit, I noticed the return (I believe) line on the left side fit pretty snug against the tank. I did have to pull one of the hoses on the right side up onto the valve cover, it looks a little squashed but I don't think it will reduce the flow enough to make a difference. I've got about 80 miles on it with the new radiators and nothing seems amiss. I used the holes on the radiator where the plastic guards fit to bolt the new fan bracket so the plastic radiator "guards" won't go back on. I'll fabricate some new guards for it soon. Doesn't look like it'll be that hard if I only guard the front of the radiator.

I would post pics of the bracket but it really is pretty ugly. Maybe once I make the rad guards I'll post some pics of both.
 
What aftermarket radiator is everyone running? My 630 has a nice puddle of coolant under it currently from a spirited ride yesterday. I can't find much except Mylers. There are some cheap ones on ebay too but I usually don't do ebay. Before I pull the trigger on a tc250 set of radiators I'd like any input you guys may have. thanks

Cody
 
CODYs said:
What aftermarket radiator is everyone running? Before I pull the trigger on a tc250 set of radiators I'd like any input you guys may have. thanks
Click to expand...

I'm interested in this too...my odo is around 400km, still bone-stock and it overheats easily. I think the lean stock setting makes it overheat that much easier than if it was set on rich. the coolant level decreases after every daytime ride and my last ride had additional cracking/pinging sounds coming from the motor every time I hit the throttle generously :banghead: I really hope I didn't blow a gasket...tried running the engine with the radiator cap off and there was no air bubbles so I hope that's a good sign.

Good lord did they neglect to keep us tropical islanders in mind when they were designing this bike. it's too freakin hot out here to be running lean with shitty rads...my air cooled TTR don't even overheat this bad, so I dunno :(
 
Get her richened up, make sure you're running premium fuel, and see what happens. They can be so lean stock (even w/ PU) that if you get so so gas something may get hurt at high load/hi rpms. I've never ever overheated.

.
 
CODYs - I'm running GPI radiators for a te250 from ebay, seem to be holding up quite well (and a few members report on their durability Here http://www.cafehusky.com/threads/chinese-radiator-upgrade.29321/)
Although with the poor finish quality you can see why they're cheap.

DYNOBOB said:
I've never ever overheated.
Click to expand...

I have


Numerous times when doing dirt trails between 0 and 10km/h (i guess guys in the US may call it single track) with guys on 250's and 450's
The new radiators didn't seem to make much difference in cooling capability but i wasn't expecting any. More like it needs another fan (or even oil cooler) if I want to do that stuff

But I don't think the 630 was designed for that. Fun none the less :D
 
DYNOBOB said:
Get her richened up, make sure you're running premium fuel, and see what happens. They can be so lean stock (even w/ PU) that if you get so so gas something may get hurt at high load/hi rpms. I've never ever overheated.

.
Click to expand...

I always run premium fuel...and I'm just about to go the PU route. waiting for it to come in the mail.

that pinging/cracking noise scared the shit out of me, but luckily it was only that one time. I let the bike cool down for a few minutes, topped off the coolant and it was gone

maxyb said:
CODYs - I'm running GPI radiators for a te250 from ebay, seem to be holding up quite well (and a few members report on their durability Here http://www.cafehusky.com/threads/chinese-radiator-upgrade.29321/)
Although with the poor finish quality you can see why they're cheap.



I have


Numerous times when doing dirt trails between 0 and 10km/h (i guess guys in the US may call it single track) with guys on 250's and 450's
The new radiators didn't seem to make much difference in cooling capability but i wasn't expecting any. More like it needs another fan (or even oil cooler) if I want to do that stuff

But I don't think the 630 was designed for that. Fun none the less :D
Click to expand...

It's weird that my yamaha airhead is fine in ANY heat, city or trails...there's the occasional clutch slip when it's reaaally hot but other than that it's fine. While the 630 though multiple times more expensive than the yammie (and looks waaay more tech advanced) seems to hate any heat.

And thanks for the rads reference, though I won't be able to get anything off ebay...might have to order an oem TE250 rads then :cry:

BTW, if you ever decide on adding another fan, do post it up. It'll be a ton of help for me
 
riz said:
It's weird that my yamaha airhead is fine in ANY heat, city or trails...there's the occasional clutch slip when it's reaaally hot but other than that it's fine. While the 630 though multiple times more expensive than the yammie (and looks waaay more tech advanced) seems to hate any heat.

And thanks for the rads reference, though I won't be able to get anything off ebay...might have to order an oem TE250 rads then :cry:

BTW, if you ever decide on adding another fan, do post it up. It'll be a ton of help for me
Click to expand...


The Yammie may be getting hot (hotter than the husky) too, it's just the yamaha doesn't have water cooling so there's nothing to boil over to tell you it's HOT.
Also, remember the 630 makes a lot more power than the yamaha (power = heat)

What conditions are you in when your 630 "overheats"? (and do you know what temp the engine is getting?)

Don't get OEM radiators, the ones that i have are welded aftermarket and hence (in theory...) are less prone to leaking For example: http://tinyurl.com/pxdvjrd . OEM te250 radiators i presume will be similar if not the same as the stock 630 radiators



Is there a reason why you can't get radiators from ebay?



An oil cooler/extra fan is on the long list of to do's...
 
riz said:
that pinging/cracking noise scared the shit out of me, but luckily it was only that one time. I let the bike cool down for a few minutes, topped off the coolant and it was gone
Click to expand...


Oh, and i had the problem of always topping off the radiator too (the service manager told me off after the first service :doh: ). In the workshop manual they specify that the tanks run a little lower than full-to-the-brim.

In turn you'll just be filling up the overflow bottle as the radiators keeps the water level at that same level.
And then you're diluting the coolant and letting coolant flow out the top of the overflow bottle.
 
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