Oil Cooler Mod GS650-GX

[Guest]

Hey guys, So now I have all the parts to do the oil cooler install on my bike...except the oil pan gasket(should show up anytime now).

I did a soft mock up on the cooler itself, everything seems to line up correctly, so its a go. The cooler and lines are from a gs700 and the oil pan is from a 650 katana. The cooler will require a bit of modification to the bracket to fit the 650 frame but that should be pretty easy. Once I get the oil pan on and hook up the bottom of the lines to the pan I will know exactly how to mount the cooler. It looks like the only thing I might need to relocate is the horn.

Heres a pic of the mock up..

Anyone know if I got the lines to the top of the cooler on right?? It seemed to be the only way I could get the bottom of the lines to the spot on the oil pan where they need to be.

[yaddy]

Hey Bribird,
that cooler mod is gonna be sweet, can't wait to see it finished.

Anyway, see on this pic of my katana frame, that little square mounting lug in front of the coil mounts is where the horn relocates to, it has a little bracket to bolt it to there, then the horn sits just inside the frame. I can bob a couple of pics of the horn bracket on if you like so you can see what i mean? Probably not much good if you don't have this mounting lug as part of your frame though?



EDIT:
After looking at your pic again, your horn probably mounts to this lug anyway doesn't it? So the shape of the bracket may just want altering so the horn sits on the inside of the frame.

[Nessism]

Did you see this thread... http://www.thegsresources.com/_forum...d.php?t=139701

Several good photos of the stock 650 oil cooler set up.

[Bribird]

Thanks Yaddy, and thanks for the oil pan!! I dont have that mounting lug on my frame but I will figure something out...there is a unused bolt tap right above the horn...I dont think it will be unused for long..

Hey Nessism, Ya.. I did not go with the exact oil cooler set up like on the Katana 650... I am gonna use the oil cooler and lines from a 85 GS700 and the oil pan of course is from the Kat. The oe oil cooler on the 650 runs the lines straight down out of the bottom of the cooler to the pan. On the 700, I think the lines kinda tuck around and ride inside the frame down to the pan...??

Also just got back to the house and my oil pan gasket has showed up...

My job is really starting to mess with the progress of my little projects...lol


time to go back to work.

[Bribird]

So I did a bit of measuring on the oil pan to oil cooler with the lines all hooked up...it really seems like everything will work just dandy. Also at the shop today I blasted and painted the lines and cooler. I am waiting for some powder to show up so I can do the oil pan to match the motor...then its time for the install.

heres some pics

[Nessism]

Nice work. First rate.

[Bribird]

Thanks Nessism!

I am thinking I will be in a position next weekend to do the complete install on my bike....looks like the hardest part will be pulling the exhaust and oil pan off.

I should have my powder on monday or tuesday at the latest, then everything will be done with the exception of the oil cooler bracket. I dont want to drill the holes for mounting it to my frame until the oil pan and lines are in place(full mock up). Then a quick trip to the blasting room and then powder the bracket and install.

[Bribird]

So heres a new pic of the cooler and lines now that the paint is fully dry.

[yaddy]

Verrrrry nice Dude,
You have an eye for the details buddy, that's for sure.

[JTsGS650]

Looks great. Thanks for all the beautiful pics too.

[Bribird]

Thanks Yaddy and JT!!

I got my powder in today and went back to the shop to do some coating.. Got the oil pan all done. Just got some big bolts left to do, and thats it. Thanks again Yaddy for the hook up on the pan!!!

[skidMarkNZ]

the horn on my 650 hangs down off a bracket where the loom earth goes at the front (just below and behind where the mounts are for the front of the tank)

hope that helps some what.

[yaddy]

NP Dude, least i could do after the hard work, effort and parts you put into my build. Just get it on there and enjoy!

Looks awesome btw, top notch job, well done.

[Bribird]

So tomorrow is the big day for the oil cooler mod. I have found an alum washer for the oil lines that I was missing. The paint on the cooler and lines has had all week to cure. I am thinking I can get it all done tomorrow. I will post pics when I get back from the shop tomorrow.

Also, one problem....when I pulled the bolt and spring out of the side of the oil pan...a little metal cap fell out(hollow cylinder....sealed at one end). I have looked on the fische and it does not even show it. I would imagine the spring goes inside of the cap, but dont know for sure since it fell out so fast I did not see which way it was turned. Once the oil pan is on the bike..I dont think this will be an easy thing to change because of the frame. Also just wanna make sure I put it together right.

So if any of you guys have been inside your factory oil cooler oil pans and know which way that thing goes....well that would be great to know.

[Bribird]

Finished

Hey all, Got the oil cooler mod all done about an hour ago. I took it on about a 20 mile test drive, and stopped a few times to check for leaks. No problems to report. The oil cooler gets hot so I know the oil is going thru it. The oil pressure light never even blinked at me. And also got to change out my dirty engine assembly oil in the process. So all is good now, fresh amsoil, new oil cooler, and even got a chance to polish the exhaust up really good while it was off the bike.

I forgot to take the camera with me to the shop this morning, so no during the process pics. But heres a few of the finished product.


Special thanks goes out to my man Yaddy who scored me the oil pan, along with Jetta who hooked me up with the cooler, bracket, lines and bolts! THANKS GUYS!!