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Fresh start on the old topic.







What I used:



http://www.motobike.jp/ [Item]: POSH An Exit Of The Oil For Oil Coolers Type1 (COLOR: Black)[924029-(03 : 06)] Merchandise 8,400Yen / Delivery Charge 2,400Yen / Total 10,800Yen (exchange rate at the time $109 US dollars)



http://www.summitracing.com [Item]: SUM-220687 -06 90 HOSE END SWIVEL (2) $28.85 [Item]: SUM-230606 S.S. HOSE -6 6FT $28.90



http://www.napaonline.com [Item]: Thermo Sleeve Heat Barrier Part# BK 7353967 $24.99



Power steering cooler from mid to late nineties Dodge 2500 fullsize truck. Local salvage yard $10



O-rings for adapter from local hydraulic shop $1



Add to that parts I had on hand: Two screw type hose clamps, a few nylon zip-ties, a line clamp, a few inches of heat shrink tubing, a metric self tapping screw to mount the cooler, a foot of self sealing silicone tape and a straight metric threaded -6AN 90 degree fitting. (hopefully , TWHunt.Fish will have a part number and price for that fitting?)
 

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I was screwing around on the oil cover website checking the prices and I'll be dammed I just wanted prices but I got the "thank you for agreeing to buy this" page.. Uh ohh... Well lesson learned & I guess i'm on the path for a cooler install. Thanks for the parts links!!



Another source for thermosleeves LiNk



I settled on a new perma-cool 1002. I don't have any boneyards near me.



08-2-10

Got almost all of my parts today. The metric nitrile oring I'm using is just a whisker to small in diameter but it will work. The measurements on its box are w3.5X I.D. 47.7 whatever that means to you all.

It was part of a blue harbor freight o-ring assortment kit.
 

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I got the folks at my local napa stumped trying to get me fixed up for that fitting.



Edit:

I got a lead for that pesky fitting over at ADV. to fit the 14mm X 1.50 oil cap threads.



www.pegasusautoracing.com

Part # 3242-033 single banjo bolt 14mm X 1.50 thread $12.49



Part # 3265-49 6an to 14mm single banjo adapter $22.49



Part # 3278-M14 Five pack of 14mm crush washers $ 4.99



Update..

While not as pretty as the other setups I've seen it works great & no leaks. I've got about 400 miles on it now. When I'm trail riding **** does the cooler get hot ! I am keeping the original filter cover in a tool tube should my cooler somehow fail on me out in the boonies.



I seem to average a 15-20f temperature drop from the inlet to outlet side of the cooler when the bike is not moving.

.

I fabbed up a hunk of stainless that I bolted on the the engine mount bolts and bolted the cooler to it. I didn't want to drill and tap the downtube. So if I decide to remove the whole cooler rig you would never know it had been there.



The banjo bolt bottomed out on me and I had to shorten it about 4 threads.



Another Edit: I now have the tw specific clarke tank on and I did not have to move my cooler setup






I used hydraulic thread locker on the fittings.

2014 edit. I'm still running this crude setup with good results and no leaks. Although my cooler fins are beat to crap.

2015 edit same as 2014 edit only beat up some more :)










 

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I sent you a PM at ADV, but wasn't sure if you checked them there.



Any chance of posting up some pics of the other side of that adapter block? I seem to remember that you need a different bolt to open up an oil passage, but I don't recall the details.....





I got the folks at my local napa stumped trying to get me fixed up for that fitting.



Edit:

I got a lead for that pesky fitting over at ADV.



www.pegasusautoracing.com

Part # 3242-033 single banjo bolt 14mm X 1.50 thread $12.49



Part # 3265-49 6an to 14mm single banjo adapter $22.49



Par # 3278-M14 Five pack of 14mm crush washers $ 4.99
 

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I posted this on the old board. I need a reference for an enquiry about it hence the addition here.



--------------------

There is a current thread about making an alternative to the expensive but classy Japanese oil cooler kit. I am retired but have kept my CAD/CAM & cnc machining centre on which I do hobby jobs. Making my own oil filter/oil cooler cover is the latest. I will add some notes which could be of interest.







1. The kit. The first cover (short one) was similar to the Japanese one but I then made the longer one as it makes for simpler & neater plumbing.



2. The 2 hoses. Teflon tube with stainless steel brading. The banjo fittings are not the same. The short ones are original. The long ones were made for me by silver soldering two parts together as no more originals were in stock. (I am in Cape Town which is really a small provincial city. Johannesburg is the industrial center of South Africa where proper stock of stuff is available.) The resulting hose is that much longer as you will see later.



3. The two fittings available. My plan was to use the straight ones on the oil filter cover and the banjo ones on the oil cooler - that is how it is usually done. I bought a length of hose to cut to size with everything mounted on the bike and then have it swaged together. When I fitted it all together I saw that it would be much neater if I made a longer cover so that i could use banjo fittings both sides and run the hoses under the exhaust.





4. I have quite a lot of experience in industrial pneumatics. There the straight & banjo fittings are interchangeable. They either have 1/8 or 1/4 BSP threads (smaller & larger sizes also available). I measured the thread on the straight fitting - it is 1/4 NPT so i had to buy a tap as i had 1/4BSP. When I came to assemble it all i found the banjo is not 1/4; it is M12x1.5. It screws in but is a very loose fit. I used it but it soon came loose. I then made M16 brass bushes with the correct M12x1.5 inner thread and fitted those to the oil filter cover & oil cooler. I had to buy that M12 tap also as the standard taps that I have are 1.75 mm pitch.

5. Those are Dowty seals on the banjo fittings.





They are hydraulic seals with tiny rubber seals moulded on the inside. I used them because I was not able to torque the banjo fittings properly in the 1/4 threads to crush a copper gasket. I hope they will survive the high temperature environment. Dowty is a British company that supplied the hydraulics for aircraft undercarriage during WW2 - at least that is where i best know their name from.



6. The oil cooler is from a used motorcycle spares place. Comes from some Kawasaki. It was quite expensive. I am told a much cheaper alternative are automatic transmission oil coolers from cars.



7. You can see that I had to snake the one tube a little because it was longer than intended.





8. I welded a small bracket to the frame. The oil cooler came with rubber bushes in the mounting holes. The flexible hoses don't exert any force on the cover or cooler.





9. It is dramatic the temperature difference if you put a finger on top of the two banjo fittings.



10. There are three oil outlets from the oil filter chamber. On the back wall is a small outlet leading up to the cams - it gets its oil from the 4 little holes on the back end of the oil filter. the crankshaft gets its oil from the main outlet at the center of the back of the oil filter. The cover leads oil to the transmission. It is this oil on its way to the transmission (& chain sprocket outrigger bearing) that goes through the oil cooler.



11. I will have it anodised black & engrave a design on the cover.
 

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Perhaps it is just 'ego', but here is another home grown option. Has been in place for a couple of years with no issues, and it does cool the oil as my temp. gauge verifies. Off the beaten track, for sure. Works well and the cost is pretty much nothing more than about 10' of 1/4" copper tube. Gerry











 

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I like that cooler w/fan idea. My engine temp gauge hardly moves as long as there is airflow (even wound to the throttle stop for hours at a time on the highway) but at idle it climbs very quickly.
 

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Though seperate from my oil cooler, once activated, the oil temp. drops noticeably. This axial fan was presented to flow 82 cfm. If I recall it was around $65 and have worked great so far. The motor however is not sealed like the Spal unit used by Ronnydog. Gerry
 

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Is there a kit now available in the U.S. that a TW 200 rider can buy and install or does it have to be a piece meal thing?



I am interested in developing an oil cooler, perhaps one with a small fan too, that is plug and play for the TW 200.



I own two of the TW's and have all the CNC equipment and CAD/CAM necessary to do the job of making the machined parts.

I may bring in one of my fluid power guys to coach us on what to do to make this.



If there's someone on the forum who is going to offer this I will back off and just order from them but if not, let me know and that means

I'll need some guidance.



I'm very willing to learn what it takes to get this done and to offer a nice product for a reasonable price.



Please send me a note and I'll listen before leaping.



[email protected]



Thank you,



Ken
 

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There has been 'lots' of interest and 'lots' of talk. We had a forum member present a pump cap to re-route but soon after left the forum. I am under the impression that vital parts (pump cap) needs to be brought from Asia. The vendor seems real good about shipping promptly but price is high. Not sure what most would be willing to pay (per my previous comments). Good luck, this maybe right up your alley. Gerry
 

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I'd like to develop a nice turn key plug and play kit for this oil cooler.

Is there a need for a temp gauge to be included?

Is there a real need for a fan?

Kinda like to keep it simple but if most would want a gauge I can understand.

The fan will require electrical hook ups which adds to the project.
 

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Admittedly both my cooling coils and fan are unique, as is Ronnydogs. In my opinion, my fan pretty much doubles the cooling potential of my 'system'. As a general unscientific example. I have been riding with an oil temp gauge for a while; moderate slow dirt climb of 2 miles at 10 to 15 mph, ambient temp 76 degrees. Stock, no cooler, I would say expect to see your oil temps around 315. With cooler only, seems I would guess 278. Cooler and fan, what I see is around 248. Again, these are only general recollections. Gerry
 

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If I were going to make a kit, I would do a basic cooler kit, then offer a guage kit and/or a fan kit separately...
 
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