Originally Posted by Onederer
You have designed in too many points for potential oil leaks, rattles and front suspension interference.
The fender is that close to the frame to allow room for the tire under it during full compression, lowering the fender may allow the tire to contact it, which depends on the tire used. No matter what type of material the strap at the top is, the bracket will most likely vibrate against the frame. For what you paid for all the fittings, you could have bought an inexpensive tubing bender and some tubing, requiring only four short pieces of hose and eight clamps to connect it all. You would still need a double flaring kit, but maybe you could borrow one because that would be expensive for a one time use. The way you mounted the cooler, you have blocked 1/3 of the direct air flow.
The first attempt is often not successful. You made your first attempt, but it is not worth praise, keep trying.
You are correct about potential problems with full fork compression, and I'm glad you mentioned this. While designing this oil cooler I realized the front wheel would strike the oil cooler with full compression of the forks. However, I don't ride hard enough to fully compress the forks on my XR650L, so I reckoned this scenario would not be a problem for me. If I were going to jump the motorcycle, et cetera, I would not have installed my oil cooler in this location.
My oil cooler installation is quite solid, and doesn't rattle. However, the installation does have enough flexibility to absorb vibration from riding. The 3/8-inch elbows have 4 hose barbs on each end, so I am confident they will not leak. I seem to be getting sufficient airflow from my drilled fender. However, I plan to cut a window in the fender, and install wire mesh if it is necessary to increase airflow.
I'm still experimenting with this installation, so I appreciate all constructive input. If I encounter any problems with my current configuration of this oil cooler, I will be certainly report them.
2005 XR650L: Shorai Battery Relocation, Spud Oil Cooler, XR650R C/S Sprocket, Reinforced Subframe, Chain Slipper Roller, Performance Design Lowering Link, Baja Designs Headlight, FMF Hi-Flo Header, ManRacks SD Rack, ManRacks Front Fender Farkle, CST Surge I Front Tire, D952 Rear Tire, Tusk D-Flex Handguards, Uni Air Filter, No-Toil Evolution air filter oil