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Has anyone tried to add an oil cooler to there bike? I came across alot of them on ebay for around $50 USD and thought it might be a good idea to extend the life of the engine.
Here are some I found:
http://cgi.ebay.com/ebaymotors/OIL-C...spagenameZWDVW
http://cgi.ebay.com/ebaymotors/PIT-B...spagenameZWDVW
Trouble is those are specific for use on Lifan Honda Cub-derived oil-cooled engines. These have very high specific outputs compared with the original Honda design and run very hot, after all they were originally designed for 50 cc and about 4 BHP. Some pit bikes have 10 BHP or more engines.
An oil cooler helps to increase the life expectancy of any engine, providing it's sophisticated enough to be provided with a thermostat for winter running. The examples shown don't have one and are really for show or pure competition.
Another advantage is the increased oil capacity which makes the oil last longer.
Looking at my engine there's a couple of mysterious bolts sealed with a copper gasket which I suspect are take-off points for the insertion of a diagnostic oil pressure gauge. That is to say they're access points to the oil galleries which are where these oil coolers connect to. You'll need the right size banjo bolts and washers and much longer hoses for use on our engine.
Yeah the trick would be to figure out if any of those bolts have oil pressure behind them which I dont think any of them do. I am going to keep looking and if I find one that will work I might put a valve on it to keep oil from going through it in cold weather but I pretty sure I wont find any that will fit our exact engine.
Been looking a bit deeper into this, and it appears that in Japan, Australia, etc Suzuki market a version of the DR200 called a TROJAN that's a utility bike, designed for farm use. It has steel rims, two carriers, round headlight, massive mudflaps and an OIL COOLER. Trouble is, I can't see any photos of where it is connected. On this photo you can see the cooler on the left side of the bike with a couple of pipes going to the right side:
http://www.suzukimotorcycles.com.au/...l%20Cooler.jpg
This is a general view of the bike. You can just see one of the black pipes crossing the back of the electric starter:
http://www.suzukimotorcycles.com.au/...anK9-SS_c1.jpg
This Suzuki Australia's web page with the DR200 TROJAN characteristics. It has lots of interesting features:
http://www.suzukimotorcycles.com.au/...09/trojan.html
Thats AWESOME!!! It looks like one of the hoses is attached to the bolt that is right under the oil filter and the other hose goes into the side of the oil filter housing which we dont have a bolt there but if this is only the return line it could go into the engine anywhere. I am thinking the hose thats under the oil filter might be the pressure line because I think that bolt is right at the oil pump.
Well from what I can make out in the workshop manual the chrome bolt right under the oil filter does have oil pressure behind it. If you look on page 101 it shows how to connect a pressure gauge to that hole to check oil pressure so all we need now is a place to return the oil and some oil lines with connection to fit our bikes. Maybe we can order the parts from Suzuki in Japan or Australia?
Page 101 of that service manual PDF shows the bolt under the oil filter as an outlet to stick an oil pressure gauge on for diagnostic purposes.
The oil pressure, by the way, is quite low, between 2.1 and 4.9 p.s.i, but this is normal on engines built with ball and roller bearings. If it had plain bearings like a car it would be a lot higher, as those plain bearings rely on oil pressure. (hydrodynamic lubrication).
It's good of Brazils STX Sundown, makers of the Qingqi under license, to come up with a service manual, seeing as the factory hasn't yet. If you have anybody near you that reads Spanish they should have very little trouble understanding 90% of it. Written Portuguese is similar to Spanish. When they speak I can't understand a thing, but writing is OK.
I think we were writing a post about the same thing at the same time...:lol8:
Just found the details of where the DR200 Trojan connects its oil cooler:
We have the bottom hole but the top one would have to be drilled and tapped...
http://upload1.zoopy.com/files/photo...cd88_small.jpg
GREAT PICTURE!!! I was at the Suzuki dealer yesterday picking up my jets I ordered and stopped to look the the DR200SE they had there, along with a bigger crankcase cover it also has a raised flat spot on the outside of the oil filter housing for the fitting to mount on and have a flat spot to seal against. In order for us to do this mod we would have to replace our side crankcase cover with the DR200SE cover, this would also be a good idea because the larger cover holds more oil and also holds a longer/bigger oil filter. Of course for our supermoto versions we would have to get it powdercoated black or it would just be the only part of the engine thats silver. I tried to find a close up of the flat spot I am talking about but this is the best I could find. I put a red circle around it.Quote:
Originally Posted by forchetto
UPDATE: The Suzuki DRZ 125 also shares this same side cover as the DR200SE. The price for this part is around $100 USD
Checking the website Luis linked to, this looks like a far easier way to add an oil cooler. It looks like the oil is pumped out of the lower hole, into the cooler and returns to the filter cover. It also looks like the filter is pushed out by the rubber washers so that the returning oil has less restriction and can flow around the filter and back into the case. Is this correct? It would seem that a new filter cover from another bike that is thicker could be drilled and tapped to accept the return line. That way the whole side wouldn't have to be purchased.
Hi guys
I read this thread, and I have some doubts.
You are saying that the silver bolt below the oil filter cover has pressure, and its a point from where the oil will come out to the radiator.
But inside the oil filter case there is the oil pump, so the pressure should be much higher here that in the silver bolt... am I right?
I'm not a expert, but I think that in our's bikes, the oil comes out from the hole B (from oil pump), pass throght the oil filter and return to the carter by the hole A (see picture below). Is this right?
Attachment 1889 Attachment 1890
If it is true, that the pressure inside the filter oil case it's higher that in the silver bolt, if we link these 2 points with a radiator, the oil will go from the oil pump to the silver bolt, right?
Another question: how can we garrantee that the oil will come trought the radiator and not just go to the hole A? can we close the Hole A? Does anyone knows where the Hole A leads to?
However, the Suzuki DF200 and the DR200 Trojan have the radiator hoses connected to these 2 points. I just don't know if that engines have a hole A or not.
Another thing, anyone knows what is the hose diameter and the radiator size of the Dr200 Trojan? just because if we install a kit with oil hoses too small we may increase the oil pressure in the system and the oil pump will go down soon.
Anyone can help?
Thank you
Mario
Super, check posts #14 and #17 here;
http://www.mychinamoto.com/forums/sh...or-125cc/page2
They show two ways to connect this all up. Both do show that the oil starts at the lower, front of the engine (second picture in your post above, where the arrow is pointing). This is where the pressure is checked according to the manual. The routing is thus; lower pressure port, to bottom of cooler, out of top of cooler, back to oil filter housing. The return to the housing can be through the oil filter cover or through the side. Some of these engines have a emboss on the side of the filter housing that can be drilled and tapped.
Another note. I believe that the oil flows from A to B (in your first picture). When I did my first oil change I noticed the metal from the break in procedure was on the outside of the filter.
oil definitely flows from A to B... so Hole A needs to be blocked, then oil is pumped from hole (2nd pics) to radiator, return to oil filter into Hole B.
Hi, sorry about posting on an old thread. I was thinking about installing an oil cooler on my motorcycle and I just need someone to confirm that I've got this right before I go ahead with it. So from what I can tell I need to drill a hole into the oil filter cover and connect one of the oil cooler hoses to that and connect the other to the hole under the oil filter housing, the part I am confused about is td_ref's post where he says that hole A in the picture above needs to be blocked but the thread ends here so I don't know if he is right or not. Could someone please confirm that hole A needs to be blocked and that it won't damage the engine or impeed the flow of oil at all?
Hi Spencer. I haven't looked at this for awhile. But to answer your question, yes, A needs to be blocked. You can see the blocking ring in the above post #12. The person's index finger is touching the ring. Normally, oil flows from A through the filter to B. When a cooler is in stalled, it flows from the cooler return (top of cooler) to the fliter housing, through the filter to B.
Ah so thats what that is. Cheers.
To save money I'm just going to get a universal one off ebay which is only £20 and attach it by drilling and tapping a hole in the oil filter cover, I'm just waiting for the useless seller to tell me how big the banjo bolts are. I'll have to figure out a way to make a blocking ring, any ideas on how I could do that?
Based on the above pictures it looks like a gasket of some kind. Take a measurement of the diameter of the filter hole and see what they have at a store that sells plumbing supplies. It would have to be oil resistant, though. Type in 'plumbing gasket' in Google Image and you'll see what I mean.
I've found just the thing http://www.ebay.co.uk/itm/GASKET-PAP...item19cdae3383
Now I just need to save up some pennies so I can buy everything I need :D
Spencer, you might want to re-think that gasket paper as it doesn't look thick enough. Here's a better picture of the gasketAttachment 6558 Notice how thick it is. It looks to me to be about 1/8" or around 3mm for the rest of the world.
Oh yeah that does look pretty thick, but couldn't I just use multiple layers of gasket paper?
Well I just measured the bolt under the oil filter and it has a 12mm thread and all of the oil cooler kits have 10mm bolts so unless if theres a way around that I'm at a dead end, I really don't want to pay £60 for the one from taobao.
Edit: problem solved http://www.ebay.co.uk/itm/12MM-BANJO...item48409198ce