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Offline pielas

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DR oil-cooler relocation
« on: August 19, 2014, 10:30:26 am »
I know many of you will probably disagree with this mod, and I have been advised not to attempt it, but because of the type of riding a do, and some other reasons, I have gone ahead and done it anyway.

The oil cooler on the DR,  gets full of seeds, and especially bugs, clogging the airflow and a mission to clean afterwards as I dont take the pressure washer to the cooler. This, together with some other reasons, have got me thinking about relocating the oil-cooler to very much the same place as is on the XR 400's, problem is there is not really enough space, so I had to put it on the forks above the mudguard.

I did a lot of searching on the internet, but could not find as single instance where this has been attempted, so I had to improvise as I went along. Bought an oil-cooler ( after some research, decided on a Setrab, made in Sweden, very good quality ) for R800 took the light assembly off and started doing checks.

Made the brackets, fitted the new oil cooler, removed the old one and connected the new hoses I had made up.

Here some pics:

From the front:






New hoses:


This was not an easy mod, mainly because the new cooler ( and oil hoses) moves with the steering wheel, and I tried more than a dozen ways to get them to function properly, found the best way was to minimize the movement by running the hoses underneath the steering stem.

Some other problems I encountered:
I had to measure the oil capacity of both coolers, as well as the extra volume of the longer hoses, and compensate by adding extra oil. I dont want all the oil in the cooling system and not have enough in the sump. New setup takes ~220ml more oil, not too bad, I can live with that.

I had to make sure that the oil cooler actually works, so I installed a proper oil-temp sensor into the banjo connector and a temporary meter on my dash. Currently it is measuring before oil enters the cooler, but I will switch it to the outlet side after I have some more averages. Temperature goes up to about 85-90 Celsius and then stops rising, seems okay.

Getting the correct hoses was a bit difficult. Hoses had to be durable, be able to handle high heat and temperature fluctuations, and have a workable bend radius. I experimented with quite a few, mainly made for the hydraulic market, but eventually settled for a 10mm stainless steel braided Teflon hose. Cost for the 1meter I needed R70 .

The headlight assembly and shroud had to move up about 2, not too difficult, with the stock light bulb, but with the longer HID bulb it would not fit as it was hitting the ignition. For now I have the stock bulb back in, but will be replacing the ignition soon with a much smaller and simpler switchboard and the HID can go back in. I have been looking for a reason to replace the bulky stock ignition for some time and now I have it.

Things still to be done:

A cover for the new cooler will have to be fabricated, in progress
Some proper brackets for the new hoses infront of the frame, the velcro straps currently used is just temporary, thinking of combining the brackets with a carbon-fibre cover for the hoses.

As mentioned, this is not finished, still needs some work, but here some benefits of the mod:
1. Oil cooler will now stay cleaner longer, bugs and grass will no longer be such a PITA to clean
2. Much better airflow across the engine, no more interference from the oil cooler
3. Oil cooler is no longer vulnerable in case of a fall or rocks coming from my front wheel
4. Servicing the oil will be easier, as I will no longer have to take the oil cooler off when replacing the oil. Yes I know it is not needed, but do yourself ( and the bike ) a favour next time you do an oil change, and take the cooler off and fill it with new oil ( takes 140ml) shake and throw out in a separate container. You will see the oil coming out is pitch-black and dirty. Seems all kind of grime is accumulating at the bottom of the stock oil-cooler in the fins at the bottom. When I do an oil change I want to ensure the new oil is clean as best as I can.

Some concerns I have about the mod:
1. It is untested, very much a prototype at this stage. The real test will be this summer.
2. Im still not happy with the movement of the hoses when turning the steering. Although it is minimal, and the hoses very hardy, I will be keeping an eye on this.
3. It is not a straightforward plug n play mod. The brackets weren't straightforward to make, and some modifications have to be done to the stock system. I always work in such a way that should testing fail, I will be able to return to before. In this case the only permanent change I made was cutting out part of the headlight shroud at the bottom, and this I cannot put back. It is not too serious though, and I will live with it should I have to.
4. When I put the more aggressive tyres back on, there will be more vibration on the front and although everything is rubber mounted, I am not sure if this will cause problems later.

The total cost was about R1800 but I had to buy a lot of hoses and connectors while doing tests. If I had to redo it will probably be about R1100.

All questions, comments and suggestions welcome, especially negative ones as it give me time to sort out problems that I might not have thought of.
5. Go soothingly on the grease mud, as there lurks the
skid demon!  --- 1962 Honda instruction manual
 

Offline LoopSoosStroop

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Re: DR oil-cooler relocation
« Reply #1 on: August 19, 2014, 11:56:34 am »
Nice!

Also busy with an oil cooler project, but not for a DR.

Where did you have your hoses made up? Decent prices?

 

Offline LoopSoosStroop

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Re: DR oil-cooler relocation
« Reply #2 on: August 19, 2014, 12:00:39 pm »
Another one; what temp measurement did you use and where did you get it?
 

Offline pielas

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Re: DR oil-cooler relocation
« Reply #3 on: August 19, 2014, 12:16:27 pm »
I got the hoses from some place in Germiston, for free, cant remember the name of the place but can look for them if you need. had them crimpted at some placed in Centurion, again, will come back to you as soon as I remember t he name.I only needed a meter. Have a meter teflon 12mm left if you want. If I have to redo I wont use these hoses though, a bit difficult to work with ( bend radius, twisting, and cannot use the usual hw-shop clamps). It is a low pressure system, and any decent oil hose that can handle 120 celsius will do.

I bought a temp-gauge designed for cars, and had the banjo drilled to fit the sensor. Cost was about R150 at autozone

What bike are you working on?
5. Go soothingly on the grease mud, as there lurks the
skid demon!  --- 1962 Honda instruction manual
 

Offline LoopSoosStroop

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Re: DR oil-cooler relocation
« Reply #4 on: August 19, 2014, 12:39:47 pm »
I got the hoses from some place in Germiston, for free, cant remember the name of the place but can look for them if you need. had them crimpted at some placed in Centurion, again, will come back to you as soon as I remember t he name.I only needed a meter. Have a meter teflon 12mm left if you want. If I have to redo I wont use these hoses though, a bit difficult to work with ( bend radius, twisting, and cannot use the usual hw-shop clamps). It is a low pressure system, and any decent oil hose that can handle 120 celsius will do.

Please do post the names, I'll have to have the hoses made up from scratch with 14 mm and 12 mm banjo's either side.

I bought a temp-gauge designed for cars, and had the banjo drilled to fit the sensor. Cost was about R150 at autozone

Ok, digital or analogue?

What bike are you working on?

TTR250
 

Offline pielas

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Re: DR oil-cooler relocation
« Reply #5 on: August 19, 2014, 01:22:10 pm »
The hoses I got from Hydroscand  http://www.hydroscand.co.za/  very helpfull and have a vast amount of connectors, fittings, etc. Have a look at the hose catalogues ( i think there are 3 of them), they show icons next to every hose showing what it can be used for. Place is a bit difficult to find though, let me kn ow if you are going that way and i will help.

The crimping and most of my connectors I got from a place about 4 shops away from Offroad touring and adventure in Jacaranda st, centurion. I think the guy was Connie that helped me, very nice and knowledgeable bloke. If you need banjos etc let me know, I still have a couple 12mm left. best thing is to visit them and explain what you want to do, they have a lot of ideas and know what fittings/hoses, etc are available. I also have a voucher for a couple of rand from them, as I was able to return the stuff I didn't use while testing  :thumleft:

Let me know if you need help or want to have a look and I can stop by Midrand anyday.



5. Go soothingly on the grease mud, as there lurks the
skid demon!  --- 1962 Honda instruction manual
 

Offline LoopSoosStroop

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Re: DR oil-cooler relocation
« Reply #6 on: August 19, 2014, 01:51:22 pm »
I'm only receiving the cooler (from a SV650, found on eBay) next week, so after I've made the brackets I'll be able to measure the hose lengths and go somewhere so they can make them up for me.

I want banjo/crimped ends because on the TTR the oil cooler routing is between the pump and oil filter. In other words, if the oil cooler leaks/ blocks or goes, the engine gets no oil pressure. 
 

Offline LoopSoosStroop

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Re: DR oil-cooler relocation
« Reply #7 on: August 19, 2014, 01:54:49 pm »
If you want I can take over those 12 mm banjos, oil line and voucher, then you make something back.
 

Offline ZA

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Re: DR oil-cooler relocation
« Reply #8 on: August 19, 2014, 02:41:53 pm »
Baie cool, ek sal nou graag wil sien hoe goed dit werk in die somer en in ry-stop situasies. Ek neem aan dit neek nie rond met die vloei van die olie nie? Los die carbon fibre gedagte, die steel look is mooi.

All in all flippen NICE  :thumleft:
 

Offline pielas

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Re: DR oil-cooler relocation
« Reply #9 on: August 26, 2014, 10:57:38 pm »
If you want I can take over those 12 mm banjos, oil line and voucher, then you make something back.

No problem, PM sent  :thumleft:
5. Go soothingly on the grease mud, as there lurks the
skid demon!  --- 1962 Honda instruction manual
 

Offline Morokai

Re: DR oil-cooler relocation
« Reply #10 on: August 29, 2014, 02:52:03 pm »
Goeiewerk  :thumleft:
Is baie nuuskierig om na jou toetsloopies te hoor hoe die mod gevaar het.
Ek sal hierdie post met altwee oe dophou
Fear is temporary, Regret is forever.

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Offline LoopSoosStroop

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Re: DR oil-cooler relocation
« Reply #11 on: September 17, 2014, 09:29:00 am »
Hier is my setup Pielas. Dankie weereens vir die raad en die voucher. Daardie manne weet wat hulle doen, en my hoses is super solid.



Olie ruil vat 1.5 l, 200 ml meer as stock.
 

Offline pielas

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Re: DR oil-cooler relocation
« Reply #12 on: September 18, 2014, 09:40:25 pm »
Lyk great  :thumleft: Groot plesier.
5. Go soothingly on the grease mud, as there lurks the
skid demon!  --- 1962 Honda instruction manual
 

Online LouisXander

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Re: DR oil-cooler relocation
« Reply #13 on: December 01, 2014, 08:49:35 pm »
Hey Eben, ek wil n DR200 oilcooler op my XR600 mount, gee raad asb!!!
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Offline pielas

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Re: DR oil-cooler relocation
« Reply #14 on: December 02, 2014, 08:38:14 pm »
Hey Eben, ek wil n DR200 oilcooler op my XR600 mount, gee raad asb!!!


My eerste raad sal wees dieselfde as wat ek gekry het: " Nee man jou moroon, moenie, die ding werk goed soos dit is hoekom wil jy fok daarmee?"

Ek het dit geignoreer en is tans nog baie happy met die mod.

That said, the DR is a wet sump with an oil cooler already, the 600R is dry sump without an oil cooler to start of with. The dry sump should not be a problem, My XR 400 is dry sump and the oil cooler works brilliantly.

SIt back, open a beer and think this through thoroughly. The oil system is critical and making a mistake can lead to serious ( and costly) trouble. It will be probably be effective , but do you really need it? Is your 600 running hot and if so how do you measure it?

My first thought would be to try to find a XR400 cooler, but I assume you already have a cooler from a DR200. As such you will have to mount on the side of the engine, which I dont like and the main reason I moved mine. I am not too familiar with either ( XR600 or DR200) so Im not sure about mounting points, hoses, etc.

I did a quick google and found this :

http://bikestuff.co/how-to-fit-an-oil-cooler-to-xr600r/

Maybe some better advice can be found there. Looks good though. If you have the standerd light I would go for the XR400 cooler, mounted on the steering stem instead of the forks. Mounting on the forks like I did was not easy.
5. Go soothingly on the grease mud, as there lurks the
skid demon!  --- 1962 Honda instruction manual
 

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Re: DR oil-cooler relocation
« Reply #15 on: December 03, 2014, 01:44:39 pm »
Eben, want to go the same route as you, beneath the headlight. Know which pipe to cut on which I need to add the hoses.

Cooler maybe bit big and I'll have to do a totally different headlight setup, but that I want to do and add LED spots instead of std headlight.
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Offline grego

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Re: DR oil-cooler relocation
« Reply #16 on: December 08, 2014, 09:57:55 am »
could you please post a pic of your banjo bolt temperature sensor?
might be an idea to terminate the ss braided teflon hoses just before the cooler, then runs short lengths of flexible rubber hose to link the teflon hoses to the cooler? that way the rubber hoses will do most of the bending/flexing.
 

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Re: DR oil-cooler relocation
« Reply #17 on: December 08, 2014, 10:07:14 am »
En nog 'n ding...

Pielas - where did you buy the cooler from?
www.majita.co.za - we sell tools!

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Re: DR oil-cooler relocation
« Reply #18 on: December 08, 2014, 10:35:36 am »
Watching with big interest!!  :sip:
 

Offline pielas

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Re: DR oil-cooler relocation
« Reply #19 on: December 08, 2014, 05:39:48 pm »
could you please post a pic of your banjo bolt temperature sensor?
might be an idea to terminate the ss braided teflon hoses just before the cooler, then runs short lengths of flexible rubber hose to link the teflon hoses to the cooler? that way the rubber hoses will do most of the bending/flexing.

Hi, I had the banjo drilled and a nut for the sensor soldered to the banjo. The oil temperature sensor can be seen on the second pic. Initial idea was to a sensor in each of the banjo's, with a toggle switch going to the meter, so I can easily compare temperatures before and after the cooler, couldn't find another sensor though without buying the whole kit.

FOr now the teflon hoses are working very well, but will definitely look at replacing the last part with rubber if the bending becomes a problem. Great idea!!
5. Go soothingly on the grease mud, as there lurks the
skid demon!  --- 1962 Honda instruction manual