SuzukiSavage.com - Oil Cooler so Far

Ed L.

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Oil Cooler so Far
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. Cheesy

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Silver '02, clubman handle bars, Cobra headlight, Sportster muffler, K+N stock air filter, 152.5 main, Superbrace, oil cooler, 1/2 inch aluminium plate forward controls, spark advance, goes like stink

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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: Oil Cooler so Far Reply #1 - 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.
Back to top	1998\|MAC muffler\|ceramic coated header\|K&N air filter\|Amal Mk2 carb\|Odyssey battery\|iridium plug\|NC windshield\|Dunlop 491s\|Superbrace\|EBC brake rotor\|12.5" Progressive shocks\|Kuryakyn ISO grips IP Logged

vroom1776 Serious Thumper Offline Posts: 2110 Gender:	Re: Oil Cooler so Far Reply #2 - 08/11/06 at 13:36:18 Good work Ed! Can't wait to hear/see/read the final results! V
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Ed L.

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"We All go a
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Re: Oil Cooler so Far
Reply #3 - 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/

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Silver '02, clubman handle bars, Cobra headlight, Sportster muffler, K+N stock air filter, 152.5 main, Superbrace, oil cooler, 1/2 inch aluminium plate forward controls, spark advance, goes like stink

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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: Oil Cooler so Far Reply #4 - 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.
Back to top	1998\|MAC muffler\|ceramic coated header\|K&N air filter\|Amal Mk2 carb\|Odyssey battery\|iridium plug\|NC windshield\|Dunlop 491s\|Superbrace\|EBC brake rotor\|12.5" Progressive shocks\|Kuryakyn ISO grips IP Logged

thumperclone

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Re: Oil Cooler so Far
Reply #5 - 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.

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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10661 Oklahoma Gender:	Re: Oil Cooler so Far Reply #6 - 08/12/06 at 20:14:40 OUTFRANKENSTANDING!!
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Reelthing Serious Thumper Alliance Member Offline Fish or ride that is the question Posts: 5397 Houston,Tx Gender:	Re: Oil Cooler so Far Reply #7 - 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?
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Ed L.

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"We All go a
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Re: Oil Cooler so Far
Reply #8 - 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. Undecided

Oh yeah, a big thanks to Lancer, couldn't of done the cooler without the oil flow diagram he posted on another thread.

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Silver '02, clubman handle bars, Cobra headlight, Sportster muffler, K+N stock air filter, 152.5 main, Superbrace, oil cooler, 1/2 inch aluminium plate forward controls, spark advance, goes like stink

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PerrydaSavage Serious Thumper Alliance Member Offline Riding "The Rock"! Posts: 3522 Republic of Newfoundland Gender:	Re: Oil Cooler so Far Reply #9 - 08/13/06 at 13:21:04 Good Job! Way Cool! Keep us posted on how well this mod works man!
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JerryAssburger Ex Member	Re: Oil Cooler so Far Reply #10 - 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....
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vroom1776 Serious Thumper Offline Posts: 2110 Gender:	Re: Oil Cooler so Far Reply #11 - 08/14/06 at 09:10:44 NICE!
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Ed L.

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"We All go a
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Norman Bates

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Re: Oil Cooler so Far
Reply #12 - 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.

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Silver '02, clubman handle bars, Cobra headlight, Sportster muffler, K+N stock air filter, 152.5 main, Superbrace, oil cooler, 1/2 inch aluminium plate forward controls, spark advance, goes like stink

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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10661 Oklahoma Gender:	Re: Oil Cooler so Far Reply #13 - 08/14/06 at 12:34:41 Well done.
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thumperclone Serious Thumper Alliance Member Offline PGR rider riding with respect Posts: 6054 Grand Junction Colorado Gender:	accessoryinternational.comRe: Oil Cooler so Far Reply #14 - 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
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