Let me start by saying this is def the best mod I've done to my Rancher yet. The way I did mine was to get some angle iron to make the part to bolt to the rack and then just some 1.5" flat stock 1/8" thick I think and made a U shaped holder that you bolt the Rad to and then just welded the U shaped tray to the angle iron sides. Heres some pics of my 420 during the relocate and after getting it painted and all.











I got a section of angle iron I think it was about 3ft long and it was way more then enough, but it was all that I could find in the size I wanted. I got a piece of 1/8" thick 1 1/2" wide flatstock that was also 3ft long and was about perfect length to cradle the radiator in a U shape. You will need 2 3/4" heater hose connectors if you plan on just extending the factory radiator hoses and about 2-3ft of 3/4" heater hose to run from the ends of the factory hoses up to the top, or if you plan on just making completely new hoses you should get about 8-9ft of the 3/4" hose just to make sure you have enough to run them properly on both sides. Of course don't forget the hose clamps for everywhere you need them. I used some vaccuum hose that was laying around at work to make a completely new overflow hose, I don't know what size that was. I used a Permacool 8" electric fan for the rad cause its slightly bigger more powerfull and draws less amperage then the factory fan and is also quieter then the factory one, although you can make the factory fan work if you want. The only other things I used is a can of black engine enamel spray paint and a gal of coolant. The part# of the fan that I used from Summit Racing is: PRM-19128. I got it on sale and had a gift cert too so I only wound up paying like $25-30 for it lol. I wired the fan into the stock harness so that it would come on when needed just like the stock one, and the temp light has not come on since the relocate. If you got any other ?s let me know and I'll do my best to help in any way that I can. One caution though is to be extra super carefull when removing the radiator from under the front fender, as the fins are paper thin and will get damaged extremely easy causing a leak.

One thing I should add is that after riding for a while and adding a snorkle after the relocation, I moved the radiator hoses to a different routing. I cut a hole in the front fender for the lower hose so it just goes straight down throught the plastic instead of looping over the rack and then through the factory rad cap access hole where I originally had them ran. I still have the upper hose, overflow hose, and fan wiring running through the cap access hole.

Great post! Im sure this will help Rancher owners!

Thanks! Since doing it to mine, there has been some pics show up here and there of 420s that have relocations that look just like mine. Its kinda cool to be the inspiration sometimes lol.

I would like to add that I relocated my overflow bottle before my last ride up front with the radiator, I am still working on an idea for a permanent mount for it. But I would also highly reccomend doing this also, with it up front I didn't get a single drop of muddy water in the bottle, unlike when it was under the rear of the bike. I'll get some pics of my temporary setup up later today, and hopefully I'll figure out a good permanent spot soon and get some pics of that too.

Heres my temp setup, I've just got the overflow zip tied to the rack tucked in behind the radiator and kinda sandwiched in there between the ammo can and snorkle riser.

sent you another pm...

should have pics up of mine sometime this week... soon as i find a suitable cover for it. seems the 09 models didn't come stock with a rad cover, it was just sittin in there nekkid...

That stinks, lol I wonder if the stock cover off of a 07-08 would work? If nothing else you can go to Lowes, Home Depot, or my favorite Tractor Supply and get something that will work. Maybe some steel mesh pretty close to my stock cover or some expanded metal with smaller holes similar to what I made my floorboards out of. I look foreward to seeing the pics too.

Any other 420 owners, please feel free to post some pics and details of your relocation here too. Would love to see other ideas and opinions of how to do it too.

ok, mounted and running like a dream! took some time and trial and error due to the fact that me and my semi-pro mechanic brother are niether one experienced welders. lol. i inherited my shop and tons of metal working gear from the wife's granddad so we're just now getting around to using all the good stuff the shop was stocked with.

only differences in the OG design of yours is i used the 2" angle iron all around. found a piece of stainless steel expanded metal to use as the grille. cut, welded, and grinded it all down then sprayed the whole thing with a few coats of spray-on bedliner (in a can, found at wal-mart). gonna put some sort of design or something on the grille later on to "spice it up" a bit. great design and thx a ton for posting it up, much better and more fulfilling to do it myself rather than dropping the $$ on a kit.






the last two images are of the snorkel job i did on it. might post a how-to later when i do my other brother's rancher. i used 1.5" pvc and 1.5" spa hose. found everything at lowe's. wraped the spa hose w/thermal wrap where it ran close to the engine. ran it out of the fuel selector hole (set it on reserve and removed the knob) using two 90 degree pvc joints then used the flexible spa hose to run it up to the rack. mounted to rack with some plumbing fixtures i also found at lowe's. sealed the whole thing with rubber gasket-in-a-can and some pvc glue. i was proud of it because i didn't have to drill into my plastic and the whole package can be taken out and stock intake can be replaced in about 20 min.

thx for posting up your rad relocation! helped me out a ton! can't wait till the next bog in two weeks...

Awesome man, glad I could help. And if you were having the same kinds of overheating issues as I was before I did my relocation, you will love it! Snorkle looks good too. Doing stuff like this yourself is always cooler and more satisfying then just buying a kit.

yup, overheated the day after my first big all day mud ride with her. I THOUGHT i cleaned the rad off good enough after riding. after i got it pulled out i realized there was NO WAY to clean it properly the way it was mounted. If the orange light comes on once, that's once too many for me, it was time to move it. lol

still trying to come up with something to put on the grille though... still in the brainstorming process

Yea man, I came to the same realization when I pulled my rad out of the stock location lol. There really isn't any effective way to clean it with it still under the plastics. And I'm sure you'll think of something cool to put on it.

Hey BigCountry8825, i am about to create my own custom snorkel similar to yours. I was wondering what you did with all of the vent lines? did you move them? where did you run them? Thanks, i appreciate your post.