My Honda XR650L Oil Cooler Project

[pete]

Originally Posted by SpudRider

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

yer got heaps of gap...
the guard will get hotter sitting
in the sun on a hot sunny day
than it will ever get from the cooler ..
exspectly while moveing though the air..
Yer can put yer hand on a cooler.. they
an't that hot..

[SpudRider]

I hope you're right, but I fear you're wrong, Pete. The engine oil in the Honda XR650L bikes will frequently reach 270 degrees Fahrenheit in the oil reservoir, which is designed to cool it. Some XR650L owners have discovered their gasoline is boiling in the fuel tank surrounding the oil reservoir. 8O My cooler will intercept the motor oil coming from the engine before it sends it to the oil reservoir, so I anticipate even higher temperatures.

Spud

[katoranger]

Spud, I will go find my snips and cut a couple sections of that mesh for you today.

I have to go the post in alittle bit and will drop it then.

Allen

[FastDoc]

That's a lot of heat.

My car's oil temp runs at 180, give or take. I don't think it's ever been past 200, even on the track.

The airplane runs about 180 also.

The pickup too. 200 max while towing in the summer.

Those are the only current vehicles I have with oil temp gauges.

Sounds like a cooler was in order.

This got me wondering about the YZ. I have no idea how hot it gets but I can place my hand on the oil bearing frametubes anytime and they are never hot, never too hot to hold.

[FastDoc]

This may be a good investment, Brother Spud.

http://www.xrsonly.com/dirt-bike-par...k-honda-xr650l

I see they make one for the YZ, I may get one myself.

[SpudRider]

Originally Posted by katoranger

Spud, I will go find my snips and cut a couple sections of that mesh for you today.

I have to go the post in alittle bit and will drop it then.

Allen

Thank you, Allen!

Spud

[SpudRider]

Originally Posted by FastDoc

This may be a good investment, Brother Spud.

http://www.xrsonly.com/dirt-bike-par...k-honda-xr650l

I see they make one for the YZ, I may get one myself.

Many of the XR650L owners have been using that analogue temperature gauge for years, Doc. I bought a digital, Trail Tech TTO Temperature Gauge for less money. As soon as my last brass fitting arrives, I can plumb the TTO gauge into the oil line in front of the oil cooler.

The Honda bean counters overruled the engineers, and killed the oil cooler for the XR650L. :evil: Instead, the bike got air scoops. :roll:

Spud

[FastDoc]

I bought a digital, Trail Tech TTO Temperature Gauge for less money.

:oops: I knew that, just forgot. :roll:

[SpudRider]

That's okay, Brother Bill. A lot of XR650L owners have problems with that analogue thermometer. :roll: Water gets under the crystal, and it fogs. I think it has another problem, but I can't remember what it is at the moment. The Trail Tech TTO Temperature Gauge costs less, and is digital. However, one does need a way to insert the probe into the oil flow. Fortunately, I can use a brass, NPT tee to turn a 90 degree angle in my oil line, and insert the temperature probe in one of the openings.

Spud

[Weldangrind]

That's an excellent idea. Even without a TTO, you could install an analogue oil pressure gauge in the oil cooler line. You could install it in a discreet location that is viewable without being on the bars if you wished.

Not only would it indicate the health of the oil pump, it would also give you an idea about the state of the oil. When the pressure drops, it's time to change it.

[SpudRider]

Originally Posted by Weldangrind

That's an excellent idea. Even without a TTO, you could install an analogue oil pressure gauge in the oil cooler line. You could install it in a discreet location that is viewable without being on the bars if you wished.

Not only would it indicate the health of the oil pump, it would also give you an idea about the state of the oil. When the pressure drops, it's time to change it.

You are an intelligent, and creative man, Brother Weld. An XR650L owner, VanPelt999, attached a flow sensor to the oil line which feeds the cylinder head. It turns out the oil pressure is very low, so he used a flow sensor instead of a pressure sensor. I searched and found his posts, but all his photographs of this unit are no longer visible. :(

Spud

[Weldangrind]

You're very kind, Spud.

[katoranger]

Spud, the screen is on the way.

[SpudRider]

Originally Posted by katoranger

Spud, the screen is on the way.

Thank you, Brother Allen! The last brass fitting I was waiting for has also arrived. Therefore, I can plumb the oil cooler into the oil line whenever I decide to do so.

Spud

[SpudRider]

I will probably plumb my cooler into the oil line within the next week. Allen (Katoranger) has graciously sent me some aluminum hardware cloth to cover the holes I intend to cut in my fender. Thank you, Allen.

Now I'm wondering. Instead of cutting several large holes and covering them with hardware cloth, perhaps I should cut slots, or drill holes in the fender. I like the idea of cutting slots, about 3/16" wide, as shown in the doctored photograph below. I would leave solid material about 5/16" wide between the slots to keep the fender strong. I would probably limit the slot length to 1-inch, and leave a 3/8" wide, horizontal band between groups of slots.



I could also drill 1/4" diameter holes, with 1/4" of solid material between each hole.



What do you guys think? Cutting slots or drilling holes would eliminate the need to attach hardware cloth. Would the slots/holes provide enough airflow for the cooler? Would the slots/holes leave enough plastic to absorb rock impacts without breaking? Finally, would either slots, or holes, resisting getting plugged with mud? If a perforated fender gets plugged with mud too easily, I would probably be better off to cut large, square holes, and install the aluminum hardware cloth.

Spud