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Old 07-01-2013, 05:53 PM   #8131
Reposado1800
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Here is my oil cooler.
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Old 07-01-2013, 05:58 PM   #8132
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Steve what das DDD mean? Dont do dat?
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Old 07-01-2013, 06:04 PM   #8133
mcma111
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Fat Fingered Typing
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87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 07-01-2013, 07:17 PM   #8134
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Heres a couple of pics of my oil cooler. its from a DR200.


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Homerb screwed with this post 07-01-2013 at 07:41 PM
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Old 07-01-2013, 08:22 PM   #8135
davek181
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cooler

Here's mine. XR 400

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Old 07-01-2013, 08:25 PM   #8136
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I was going to use an xr400 oil cooler but used ones were expensive and rare. The Dr200 cooler cost me $18 posted!
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Old 07-01-2013, 08:32 PM   #8137
davek181
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Quote:
Originally Posted by Homerb View Post
I was going to use an xr400 oil cooler but used ones were expensive and rare. The Dr200 cooler cost me $18 posted!
I forget what I paid now, but I remember watching eBay for a very long time till I caught everyone else asleep and got it cheap. I think it is one of those things you gotta buy in the winter when no one else is watching.
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Old 07-01-2013, 09:07 PM   #8138
Aaron from Texas
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Quote:
Originally Posted by davek181 View Post
Here's mine. XR 400

I've been looking at doing a cooler since my climate is usually quite hot and humid... Do these XR400 coolers bolt right up to our XL's, or do they require some modification? Where is the best place to tap into the system?
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Old 07-01-2013, 09:12 PM   #8139
joexr
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Originally Posted by Kirk the Jerk View Post
Where is the best place to tap into the system?
You're looking at it.
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Old 07-01-2013, 09:50 PM   #8140
davek181
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Quote:
Originally Posted by Kirk the Jerk View Post
I've been looking at doing a cooler since my climate is usually quite hot and humid... Do these XR400 coolers bolt right up to our XL's, or do they require some modification? Where is the best place to tap into the system?
You have to weld 6mm nuts on the frame to bolt to and a little shelf for it to sit on if you want to duplicate the 400 mounting. Some have fabricated brackets to mount them on but I am not sure how they attached it to the bike.

I studied all the installs I could find when I was contemplating mine and finally just did it the way Honda did. A few feet of AN braided line and a handfull of fittings and you're done.

If you do decide to use AN lines there is a cool tool you have to get, or borrow mine, it is called Koul tool. It makes installing the fitting on the lines simple and blood free.

I just swapped some USD forks on my XL and I had read concerns about clearance with the cooler, but the forks miss it so it remains. I have pics of that too but the cooler shows better with the 400 forks.
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Old 07-02-2013, 07:21 AM   #8141
mcma111
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Quote:
Originally Posted by davek181 View Post
You have to weld 6mm nuts on the frame to bolt to and a little shelf for it to sit on if you want to duplicate the 400 mounting. Some have fabricated brackets to mount them on but I am not sure how they attached it to the bike.

I studied all the installs I could find when I was contemplating mine and finally just did it the way Honda did. A few feet of AN braided line and a handfull of fittings and you're done.

If you do decide to use AN lines there is a cool tool you have to get, or borrow mine, it is called Koul tool. It makes installing the fitting on the lines simple and blood free.

I just swapped some USD forks on my XL and I had read concerns about clearance with the cooler, but the forks miss it so it remains. I have pics of that too but the cooler shows better with the 400 forks.

The STEP is welded to the steering stop at the bottom of the head tube.
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BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 07-02-2013, 10:42 AM   #8142
davek181
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Originally Posted by mcma111 View Post
The STEP is welded to the steering stop at the bottom of the head tube.

I welded a step on also, I didn't see a good alternative. I had seen some mention of fabricating a complete bracket that somehow attaches to the cooler and somehow to the bike too. I could not imagine a way to do that without impeding airflow among other problems.

My welding skills, or lack of, lead me often down other paths if possible. I was not comfortable with welding on the side of the oil tank initially but soon enough discovered there was no other workable option. It really wasn't that bad once I committed myself to doing it. The tank is thick enough and the welds are mostly hidden once the cooler is in place.

Another problem I found is the hose layout. It would have looked a little better if I had reversed the flow through the cooler which would have allowed cleaner looking and shorter lines, running one up each side. The way Honda designed it to flow had one side (inlet) hole larger than the outlet which made sense hydraulically to me, so I ran it that way too. I tried many different combinations of line routing in my mock up but eventually settled with running the inlet and outlet up the same side and curving over the top with the inlet. It made cable and wire routing a bit of a challenge too, but in the end I think it was worth the effort. I like how it is hidden from damage and gets airflow through the headlight shroud and doesn't rely on rubber hose connections. I have learned to distrust rubber hoses and non concentric clamps and try to avoid them if possible.
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Old 07-02-2013, 11:14 AM   #8143
mcma111
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XR400 Oil Cooler

For the hose routing you could cut the OE fittings off of the cooler and either turn them around to point to the rear or simply get some AN6 fittings and have them welded on.
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BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 07-02-2013, 01:52 PM   #8144
davek181
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I suppose I could, but it is on there now and working fine. I would rather just ride than work on it. Sorta like don't fix it if it aint broke.

I am turning my attention now to a possible rear disc conversion. I have all the parts I need, just need to fab up the pedal and master cylinder mounts. All the wheels I have found are 18" too, and I would rather stick with the 17 for clearance and tire choice issues. I guess my next hurdle is to lace a 17" rim on the disc brake hub. Maybe this winter when I am not so inclined to ride.
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Old 07-02-2013, 04:29 PM   #8145
Reposado1800
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I scored a set of XL600 cases for $50. I changed my mind from ripping my original engine apart to building another one. I am going to just lurk on ebay for a while and score parts to build a XR600 XL600 hybrid.
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