My Honda XR650L Oil Cooler Project
 

The Honda XR650L employs an air cooled engine with a dry sump oil system. The oil pump sends oil to an external reservoir in the frame, and the oil is cooled somewhat by exiting the engine for a while. :) However, the smaller, Honda XR250R and Honda XR400R also came equipped with external oil coolers, as well as the dry sump engine. Honda declined to install an external oil cooler on the XR650L, and installed air scoops on the fuel tank, instead. :roll:

http://i442.photobucket.com/albums/q...foorRes020.jpg

The stock fuel tank only holds 2.8 gallons, so most riders quickly buy a larger, aftermarket fuel tank. ;) However, none of the aftermarket fuel tanks will accommodate the stock air scoops. :( Therefore, the XR650L can overheat if run at high rpms for extended periods of time. Therefore, many XR650L owners install oil coolers on their bikes.

Some people install an XR400R oil cooler on the XR650L. However, a proper installation of the XR400R oil cooler requires welding studs onto the oil reservoir. :( The XR400R oil cooler also requires a lot of special, oil hose fittings, so it is an expensive solution. :roll: In addition, this oil cooler is located in close proximity to a lot of wires and cables on the XR650L, which can easily be damaged by the heat. :( Therefore, I ruled out installing an XR400R oil cooler. ;)

Two individuals also manufacture oil coolers for the XR650L. However, I believe both are vulnerable to damage, and both are fairly expensive. Therefore, I decided to design my own oil cooler. Here is my preliminary design. I am going to add a digital temperature gauge to my final installation, as soon as I receive shipment of the NPT brass fittings I ordered. :)

http://i442.photobucket.com/albums/q...lumbing012.jpg

http://i442.photobucket.com/albums/q...lumbing022.jpg

http://i442.photobucket.com/albums/q...lumbing016.jpg

http://i442.photobucket.com/albums/q...lumbing025.jpg

Spud :)

If you're interested in learning more about the XR400R oil cooler installation for the XR650L, you might enjoy reading the following thread. :)

http://www.4strokes.com/forums/topic.asp?TOPIC_ID=22902

Two individuals also manufacture oil coolers for the XR650L. Here are links to their vendor threads describing their oil coolers. :)

http://www.advrider.com/forums/showthread.php?t=652313
http://www.advrider.com/forums/showthread.php?t=578914

My oil cooler will cost much less than half the price of any of these oil coolers. I also hope my oil hoses, oil hose fittings, cables, and electrical wiring will be less vulnerable to damage.

Spud :)

Excellent idea, Spud! I wish that the XR250R came with a cooler, but it did not. Only the XR400 came with the steering neck cooler. My cooler is limited to the frame tube acting as a heat exchanger.

I have not yet plumbed my oil cooler into the stock oil lines. The weather is cool, and I am also awaiting shipment of my NPT brass fittings. Therefore, I intend to test my placement of the oil cooler by riding the bike with the oil cooler unplumbed. ;) For the final installation I will also need to cut some holes in the front fender to allow good air flow to the oil cooler. ;) However, I don't plan to perforate my front fender until the muddy part of the riding season is past. ;)

Spud :)

Thank you, Weld. :) I guess some early models of the XR250R didn't come with an oil cooler. However, the 1990 model year did have an oil cooler.

http://www.cheapcycleparts.com/model...ssemblies/7847

http://www.xlv.ch/Bilder/xr/zubehoer/Oil-Cooler_1.jpg

Some XR650L owners install the smaller, XR250R oil cooler. However, this oil cooler requires the same placement as the XR400R oil cooler, and entails the same disadvantages. ;)

http://www.4strokes.com/forums/topic...02&whichpage=5

Spud :)

Here's another link showing the installation of the XR250R oil cooler on an XR650L motorcycle. :)

http://www.advrider.com/forums/showt...7#post16044037

http://i704.photobucket.com/albums/w...r_2009/005.jpg

Spud :)

Here's another interesting link concerning the XR250R oil cooler. :)

http://www.xlv.ch/XR/Generalinfos/Oil-Cooler.html

I considered installing this oil cooler, but I think my design has advantages over the XR250R oil cooler. My oil lines are shorter, and less likely to damage other parts of the bike with heat. My oil cooler has a much larger surface area. Also, it is increasingly difficult to find used, XR250R oil coolers for sale. Therefore, my oil cooler installation will undoubtedly cost less than an XR250R, oil cooler installation. ;)

Spud :)

Excellent work, spud!!

I decided to design my own oil cooler.

I love it Spud!

I was going to suggest a fender-ectomy or fender-otomy. Maybe a wide opening with a screen or mesh of some sort to keep rocks from breaking an oil line. Maybe a 'dry' and 'wet' season fender? Nothing wrong with running a full fender in the wet season as it's by it's very nature going to be cool enough AND even with reduced airflow to the cooler it will not be any worse than stock.

It stinks Honda cheaped out on this longevity increasing feature.

My 1996 XR250L did not have a cooler and cracked the head at 25,000 miles, I think due to overheating. I frequently ran that poor thing at 65-80 MPH on the San Francisco Bay Area freeways all year long...

Thank you, Jim. :)

Spud :)

Thanks for the good tips regarding "winter" and "summer" front fenders, Doc. :) Indeed, I plan to install wire mesh over the holes in the front fender, as shown in the photograph below. ;)

http://i1006.photobucket.com/albums/...t/IMG_0465.jpg

Can anyone recommend a good size wire mesh, and a good place to purchase it? I guess I will start looking at the local ranch supply stores, Home Depot, and Lowes for suitable material. :)

I didn't research when Honda implemented the oil cooler for the XR250R. I assumed Honda added the oil cooler in later models, but I guess Honda eliminated the oil cooler for the later models, as a cost cutting measure. :roll: Hondas are still good motorcycles, but "Mother Honda" makes a lot of decisions that way. ;)

XR650L engines will drop valve seats when they get too hot. 8O I'm hoping my oil cooler will allow me to gear up my XR650L, and make some freeway runs at high rpms later this year, without fear of toasting the engine. ;) I am adding a Trail Tech TTO Temperature Gauge to my oil line so I can constantly monitor oil temperatures. :)

Spud :)

That mesh looks like what is put up to keep squirrels out of places. Problem is that you may have to buy a roll of it. Also called hardware cloth I think. Check local hard stores.

I think I may have some galvanised mesh. I can send you a chunk of it.

Thank you for your gracious offer to help, Allen. :D I will check out my local options, first. ;) I was thinking I would like to get a finer mesh than the one shown in the photograph. Perhaps I can get a scrap piece of mesh from Home Depot. ;) As you can see, I don't need a very large piece. :)

Spud :)

Check with the local places that do window screens.