SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Oil Cooler so Far /cgi-bin/YaBB.pl?num=1155323497 Message started by Ed_L. on 08/11/06 at 12:11:37

Title: Oil Cooler so Far Post by Ed_L. on 08/11/06 at 12:11:37 Decided to take on the challenge of installing an oil cooler on my '02. Here is a teaser showing how far the project has gotten.  http://www.bikepics.com/pictures/653757/ Still looks a bit ratty but is coming along fine, just need one more trip to the hardware store for some small stuff and it will be ready to test. The cooler came off a GXSR, should of gotten the lines along with the cooler. Ended up making the pieces the hose nipples fit into. I haven't blocked any of the oil lines in the block so most of the oil will follow the orignial route. Hook up will be thru the front plug which I drilled out and brazed a 3/8 piece of brake hose into, the return will go to the brass elbow on the side cover. Thought everybody was getting tired of carbs and backfires so here is something different for the weekend. :D

Title: Re: Oil Cooler so Far Post by Savage_Rob on 08/11/06 at 12:27:45 It doesn't look too bad from that image.  Keep us posted.  This is definitely something we don't see in full repetition here.

Title: Re: Oil Cooler so Far Post by vroom1776 on 08/11/06 at 13:36:18 Good work Ed!  Can't wait to hear/see/read the final results! V

Title: Re: Oil Cooler so Far Post by Ed_L. on 08/12/06 at 11:51:15 It works, added an extra 3/4 of a quart of oil to the engine capacity. Let it idle for 10 minutes and the cooler got too hot to touch. Filling it was simple, just let the engine run for 15 or so seconds, clamped the line running to the cooler, shut the engine off and refilled to the line on the sightglass. By clamping the "to" line I was able to isolate the cooler from the rest of the engine. Did it three times and didn't need to add any more oil after the second refill. Blow by blow pictures will follow, da*m shop is close to 100 degrees, need to hit the pool and have a beer. Think this changes my '02 into a Rat or at least a Frankenstein.  Here are a couple pf pictures of the finished project  http://www.bikepics.com/pictures/654677/  http://www.bikepics.com/pictures/654680/

Title: Re: Oil Cooler so Far Post by Savage_Rob on 08/12/06 at 17:54:34 That doesn't look bad at all Ed.  I think I'd go for some braided stainless in the connecting lines though.

Title: Re: Oil Cooler so Far Post by thumperclone on 08/12/06 at 18:59:06 good looking install!saw a by pass valve by Jagg they also have a small oil cooler kit for  $27... when i had a hopped up 100 in my ct 70(honda clone) put a head breather off the intake valve tappet cover as  cheap insurance to protect gaskets from any excessive pressures that MAY be created by the higher volume of oil...saw an automatic by pass also(cant find yet) that bypasses the cooler when temp is below 50 f.

Title: Re: Oil Cooler so Far Post by lancer on 08/12/06 at 20:14:40 OUTFRANKENSTANDING!! ;D

Title: Re: Oil Cooler so Far Post by Reelthing on 08/12/06 at 20:38:30 looks right fine Ed - are you going to block the other oil path or just leave it as is?

Title: Re: Oil Cooler so Far Post by Ed_L. on 08/13/06 at 08:27:07 I'm just leaving it as is with the internal oil passage way open. Even putting a restrictor in makes me nervous. There was no real easy, safe way to block it off and keeping it open allows me to isolate the cooler with the engine running and use the sight glass to check on the oil level. Took a while to figure that out, might put a ball valve in the "to" line instead of clamping the hose with vice grips. Think a ball valve would be a good idea, then you could isolate the cooler in cold weather. An automatic temp controlled bypass valve would be cool to have but there isn't a lot of room to work  with, there is a big ol exhaust pipe in the way. I was a bit nervous about welding onto the downtube of the frame so ended up using hose clamps to attach the brackets with. Thinking about shooting the cooler and brackets with some rattlecan black paint to hide it when I get the time.    Can't get out to ride for a few days, my wife has a real bad ear infection and it looks like I'm elected to keep an eye on her till the fever breaks. :-/   Oh yeah, a big thanks to Lancer, couldn't of done the cooler without the oil flow diagram he posted on another thread.

Title: Re: Oil Cooler so Far Post by PerrydaSavage on 08/13/06 at 13:21:04 Good Job! Way Cool! Keep us posted on how well this mod works man!

Title: Re: Oil Cooler so Far Post by JerryAssburger on 08/13/06 at 22:44:01 Holy Cow! You  ROCK! God bless the people who spin wrenches and bruise their knuckles to put sound ideas into action. I REALLY can't wait to try this on my poor unsuspecting bike....

Title: Re: Oil Cooler so Far Post by vroom1776 on 08/14/06 at 09:10:44 NICE!

Title: Re: Oil Cooler so Far Post by Ed_L. on 08/14/06 at 12:19:35 Here are the down and dirty pics of tapping the return line and a shot of the oil plug I ended up modifying into a hose fitting.  Tapping the hole for the return line    http://www.bikepics.com/pictures/655182/ What the hole looked like when done    http://www.bikepics.com/pictures/655184/ Grinding a little relief so the return elbow fits    http://www.bikepics.com/pictures/656316/  A mockup of the return elbow and hose fitting    http://www.bikepics.com/pictures/655193/ The modified oil plug    http://www.bikepics.com/pictures/655187/ The cooler after a shot of black spray paint.   http://www.bikepics.com/pictures/656338/ Didn't take any pics of the mounting brackets, used 1/8x3/4 inch flat stock and a big hammer to bend them into the right shape. Any small oil cooler would work as long as there is a way to mount it, the one I used came off a GXSR. Thinking about putting a piece of aluminium over the lower half of the cooler to protect it from road debris that's been kicked up by the front tire. Still need to do an oil and filter change before riding. Now I wish the thumper had a temperature gauge to see if all this really does make it run cooler. Kind of a fun project, not something you can buy off of the shelf.

Title: Re: Oil Cooler so Far Post by lancer on 08/14/06 at 12:34:41 Well done.   ;)

Title: accessoryinternational.comRe: Oil Cooler so Far Post by thumperclone on 08/14/06 at 14:05:33 oil temp gauge>>accessoryinternational.com part code     AUG2130000 look under gauges ..think it goes where filler plug is.. kinda pricey  $109.99

Title: Re: Oil Cooler so Far Post by orrin7 on 08/14/06 at 16:22:47 looks cool. and neat job. But I have an idea. To keep from redirecting or changing any oil flow in the block. You could just modify your filter cover , put your oil lines into the passeges that feed your filter. This would be the same as using a remote filter on a car engine. Then since you would not have a place for your oem filter. You could use a peterson canister in line filter. Of course you would need to use braided hose and A.N. fittings. Also if you you wanted you could incorporate a oil pressure regulator. Well this is just my two cents worth.

Title: Re: Oil Cooler so Far Post by Ed_L. on 08/14/06 at 18:36:55 I was thinking about going that route but my machining skills aren't up to it and the oil lines would stick out and be in the way. Another way would be to just do away with the oil filter side cover and tap into the holes in the case but it seemed a little risky cause I don't know how much metal there is to work with. If I made a mistake then the entire side case would be trashed plus to do it right I'd need to pull the engine apart. Was too much work for the same results. Gotta keep it simple as possible. Would like to use A.N. fittings with braided hoses but it is real tight in a couple spots and am not sure if there is enough room. Now that it's hooked up I can swing by a hydralic hose store and see if it is possible to switch over to better fittings and lines.

Title: Re: Oil Cooler so Far Post by JerryAssburger on 08/14/06 at 21:36:11 Still, a beaut of a job no matter what. Since it's low pressure, I'm not sure what there is to sweat about the fittings. Makes me wish I had a way to braze! Isn't that done with a butane torch?

Title: Re: Oil Cooler so Far Post by orrin7 on 08/15/06 at 17:03:57 If fitting room is an issue try some 90* fittings. i use some at work that fit in really tight places. they even have a fitting called a banjo fitting that only sticks out about an inch

Title: Re: Oil Cooler so Far Post by smokin_blue on 09/01/06 at 10:07:51 If you want AN fittings check out Earl's Performance products.  In particular get into the UK site to search for parts made for bikes.  I just finished a GSX-R1100 based monster of a street fighter that I replaced the stock cooler with a 19row Earls'.  They have all the metric fittings and 90-s to 180 deg fittings to route anything.  Pricy but beautiful.  They list coolers for most all the sporty suzuki's I will have to check if they have a fittment for the savage.  The key is they have all this figured out in the UK but not in the US where the company is based.  I took the UK pn's to the US customer service and they gave me the us equivalent.  then I ordered them from a local dealer or I also found an bought some cheaper on line. I am new to the forum but I am planning a major transplant of a savage engine into a different frame to build a 60's style cafe bike.

Title: Re: Oil Cooler so Far Post by Ed_L. on 09/01/06 at 15:58:09 Thanks for the tip for fittings, I'll give them a call and see if they have anything that will work. So far the cooler works great, have ridden a lot of short trips and one 100 mile ride with no problems or leaks. I'm amazed at how much heat comes off the cooler after 10 minutes on the road, guess that means that it is doing it's job. Another plus is that it adds 3/4 of a quart of oil to the engine capacity. now that I know it works I can upgrade the hoses and fittings.

Title: Re: Oil Cooler so Far Post by smokin_blue on 09/01/06 at 18:38:08 I would also suggest taking a look at this site www.earls.co.uk It is the UK site I referenced.  You should be able to download their motorcycle catalog right on line.  The US guys are through Holley Carb company as the parent company and the customer service is terrible and they are very helpful for what you are trying to do. Good luck!

Title: Re: Oil Cooler so Far Post by JerryAssburger on 09/02/06 at 19:06:09 BRAVO, Ed-L! My hat's off to you.

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