My Honda XR650L Oil Cooler Project - Page 4

Weldangrind · 03-31-2012, 12:50 AM

Spud, did you drill into the frame?

SpudRider · 03-31-2012, 01:10 AM

No, I did not drill into the frame, Weld.

I constructed a frame of 3/4", aluminum angle iron and 3/4", aluminum bar stock. I bolted the oil cooler to the angle iron, and attached the frame to the bike with the horizontal cross pieces. The bottom cross bar is attached to a small aluminum plate behind the frame by two, 1/4"x2" bolts. Because of the location of the regulator/rectifier, the top cross bar is mounted with a plastic zip tie. I plan to replace this zip tie with a metal cable tie.

In the last photograph you can see one of the nylon spacers I used to shim the rear fender into a lower position. This particular spacer was 1/4" thick. I ultimately replaced this shim with a spacer 11/16" thick.

Spud

Weldangrind · 03-31-2012, 01:15 AM

I can see the depth by the second pic. The nylon spacers are a great idea.

katoranger · 04-03-2012, 03:39 PM

Spud, did you get the pic I sent Sunday? I think the mesh I have is stainless. It has sat outside for a year or two in the weather. Holes about 1/8 inch. Got enough for a hundred fenders.

FastDoc · 04-03-2012, 04:39 PM

Very good work, Spud. Looks 'factory.' 8)

SpudRider · 04-03-2012, 10:32 PM

Quote:

Originally Posted by katoranger

Spud, did you get the pic I sent Sunday? I think the mesh I have is stainless. It has sat outside for a year or two in the weather. Holes about 1/8 inch. Got enough for a hundred fenders.

Yes, I did receive your message Allen. Thank you!

Please excuse my belated reply; I meant to send you a PM, but I forgot. :oops:

I think the 1/8-inch, stainless steel mesh will be perfect for my fender! I'll send you a PM very shortly.

Spud

SpudRider · 04-03-2012, 10:34 PM

Quote:

Originally Posted by FastDoc

Very good work, Spud. Looks 'factory.' 8)

Thank you, Doc.

I talked to Brother Andy, a professional mechanic, and he gave me a few suggestions.

Therefore, I rerouted my hoses, and ended up with a cleaner, more robust configuration.

I'll post some photos in an hour or so.

Spud

MICRider · 04-03-2012, 10:40 PM

That looks cool! (pun intended)

I've never put an oil cooler on a motorcycle but I'm sure it will reduce operating temps substantially!

SpudRider · 04-03-2012, 11:31 PM

Thank you, Stew.

Here are the photographs of the final configuration for my oil cooler.

I am still waiting for a brass fitting to arrive, so I won't get to plumb the cooler into the oil line for a week or so.

Allen found some 1/8", stainless steel mesh for me! Thank you, Allen.

I sent you a PM.

For several reasons, I think the mesh will work better than drilling holes in the fender.

I think the mesh will be more resistant to clogging with mud. Installing the mesh will be easier than drilling all those holes! 8O I can place the fender closer to the oil cooler with mesh, since it will not melt as plastic will.

Finally, I think I will get better air flow with the mesh.

I am going to mount a Trail Tech TTO Temperature Gauge in the oil line before the oil filter. The TTO gauge will allow me to monitor oil temperatures as the oil exits the engine, before it enters the oil cooler.

Spud

FastDoc · 04-04-2012, 12:40 AM

Great work, Spud.

The TTO water temp gauge I put on the PP400 worked very well. Odd they never turn off, kinda like an old LCD wristwatch.

Remember to add some extra oil, you've increased your oil capacity.

SpudRider · 04-04-2012, 01:14 AM

Quote:

Originally Posted by FastDoc

Great work, Spud.

The TTO water temp gauge I put on the PP400 worked very well. Odd they never turn off, kinda like an old LCD wristwatch.

Remember to add some extra oil, you've increased your oil capacity.

Thanks, Doc.

I received my TTO Temperature Gauge. Apparently, it doesn't have a backlight; that's too bad. :roll: I guess you can replace the battery when it dies. Am I correct?

My Honda XR650L employs an oil dipstick, so I will be in good shape.

I check the oil level frequently. I will be sure to add extra motor oil as soon as I complete the installation of my oil cooler.

Spud

SpudRider · 04-04-2012, 01:16 AM

I have a question for everyone. How far away should I place the fender from the oil cooler? I don't want to melt my fender. :roll:

Spud

Weldangrind · 04-04-2012, 01:59 AM

Can you achieve 3/4"? That seems like a good space.

SpudRider · 04-04-2012, 03:07 AM

Quote:

Originally Posted by Weldangrind

Can you achieve 3/4"? That seems like a good space.

I'm sure I can, Weld. Right now I have about 3/8-inch space between the fender and the oil cooler.

Brother Andy has warned me I might melt my fender if I don't have enough space between it and the oil cooler. I might add, Brother Andy is always right.

I think 3/4-inch is a very reasonable space.

I will try shimming the fender down some more, tomorrow.

Spud

FastDoc · 04-04-2012, 11:47 AM

I think the TTO just uses an ordinary off the shelf button battery of some sort.

03-31-2012, 12:50 AM	#46
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Spud, did you drill into the frame? __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

03-31-2012, 01:10 AM	#47
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	No, I did not drill into the frame, Weld. I constructed a frame of 3/4", aluminum angle iron and 3/4", aluminum bar stock. I bolted the oil cooler to the angle iron, and attached the frame to the bike with the horizontal cross pieces. The bottom cross bar is attached to a small aluminum plate behind the frame by two, 1/4"x2" bolts. Because of the location of the regulator/rectifier, the top cross bar is mounted with a plastic zip tie. I plan to replace this zip tie with a metal cable tie. In the last photograph you can see one of the nylon spacers I used to shim the rear fender into a lower position. This particular spacer was 1/4" thick. I ultimately replaced this shim with a spacer 11/16" thick. Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

03-31-2012, 01:15 AM	#48
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	I can see the depth by the second pic. The nylon spacers are a great idea. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

04-03-2012, 03:39 PM	#49
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Spud, did you get the pic I sent Sunday? I think the mesh I have is stainless. It has sat outside for a year or two in the weather. Holes about 1/8 inch. Got enough for a hundred fenders. __________________ You meet the nicest people on a Honda Clone.
	0

04-03-2012, 04:39 PM	#50
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Very good work, Spud. Looks 'factory.' 8) __________________ Happy to serve.
	0

04-03-2012, 10:40 PM	#53
MICRider Join Date: Oct 2009 Location: Alberta, Canada Posts: 3,274	That looks cool! (pun intended) I've never put an oil cooler on a motorcycle but I'm sure it will reduce operating temps substantially!
	0

04-03-2012, 11:31 PM	#54
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Thank you, Stew. Here are the photographs of the final configuration for my oil cooler. I am still waiting for a brass fitting to arrive, so I won't get to plumb the cooler into the oil line for a week or so. Allen found some 1/8", stainless steel mesh for me! Thank you, Allen. I sent you a PM. For several reasons, I think the mesh will work better than drilling holes in the fender. I think the mesh will be more resistant to clogging with mud. Installing the mesh will be easier than drilling all those holes! 8O I can place the fender closer to the oil cooler with mesh, since it will not melt as plastic will. Finally, I think I will get better air flow with the mesh. I am going to mount a Trail Tech TTO Temperature Gauge in the oil line before the oil filter. The TTO gauge will allow me to monitor oil temperatures as the oil exits the engine, before it enters the oil cooler. Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

04-04-2012, 12:40 AM	#55
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Great work, Spud. The TTO water temp gauge I put on the PP400 worked very well. Odd they never turn off, kinda like an old LCD wristwatch. Remember to add some extra oil, you've increased your oil capacity. __________________ Happy to serve.
	0

04-04-2012, 01:16 AM	#57
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	I have a question for everyone. How far away should I place the fender from the oil cooler? I don't want to melt my fender. :roll: Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

04-04-2012, 01:59 AM	#58
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Can you achieve 3/4"? That seems like a good space. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

04-04-2012, 11:47 AM	#60
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	I think the TTO just uses an ordinary off the shelf button battery of some sort. __________________ Happy to serve.
	0