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The TTR250 FAQ web pages -> TTR250 -> Modifications -> Oil cooler project 2024
Post Info TOPIC: Oil cooler project 2024
tripodtiger


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Oil cooler project 2024
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I was trying to find some thorough details on fitting an oil cooler.  It's pretty messy in here, with half a dozen different threads which either drop off unfinished, or don't really give sufficient information.

What I've gathered so far is that there is one bolt, located inside the clutch cover, that is about 10mm too short.  Ite needs to be replaced with a 25mm thread length, to close off an existing oil pathway.

The redirection of the oil is then into the oil cooler, via two new bango bolts (to be obtained) fitted into the lower front of the clutch cover.  One is 'out' and the other is 'return' 

So, at the moment I don't have any of that.  I just have the clutch cover off and a spare clutch cover.

20240815_135233.jpg

Two bolts fitted on the front of the case need to be replaced with 12mm x 1.25 threads bango bolts.

20240815_135205.jpg

Bolt on the left is 12mm x 1.25 x 13mm.  It needs to be replaced with a 12x1.25x25mm bolt.

20240815_141042.jpg1.25mm 'Fine' thread pitch.  M12 is 1.5, I expect. M10 Course would be 1.75mm, I suppose.

 

20240815_135747.jpg

The oil passage is visible in the threaded hole.  It needs a 25mm bolt to close it off, redirecting oil to the cooler fittings.  You can see how the oil passageway is cast into the case cover, in this photo visible below the threaded hole.

20240815_135803.jpg

20240815_140413.jpg

3 M12 fine bolts removed from my spare clutch cover.  The copper washers will need to be prised off and replaced, I think they may be past annealing.  

 

As I don't yet have an oil cooler and don't want to have to do it again, I am going to take the spare clutch cover to a hose maker and have them make a short joiner hose between the 'out' and 'return'.  I can then fit that to the in service cover, add the 25mm blanking bolt and re-assemble the whole show ready to go.

Until I do find an oil cooler, the oil will just circulate an extra few cm through the joiner hose.  Sounds a plan.

 

Corrected 'M10' to M12.  Thankyou.

 

 

 



-- Edited by tripodtiger on Thursday 15th of August 2024 05:50:45 AM



-- Edited by tripodtiger on Friday 16th of August 2024 12:01:38 AM

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In the Riverina.

'73 RD250, '80 XS1100, '81 RD373LC, '96 Tiger 900/sidecar, '02 TTR250, and another XS11 - this time a chain drive Period 5 race bike that may be ready to race eventually.
mossproof


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Bolts are M12 extra-fine - 1.25mm thread pitch.

 

Steve has the blanking plug in his shop

Oil cooler blanking plug and washer - Totally TTRs

cheaper than ebay's  example here:

M12 x 1.25 EXTRA FINE PITCH FULLY THREADED SET SCREWS HIGH TENSILE 8.8 HEX BOLT | eBay



-- Edited by mossproof on Thursday 15th of August 2024 05:50:56 PM

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tripodtiger


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Long way to send an M12 x1.25 x 25mm bolt.

Buy one locally, cut it, run a die over it, fit it.

 

FIIK why I typed 10mm.  I'll correct it.



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In the Riverina.

'73 RD250, '80 XS1100, '81 RD373LC, '96 Tiger 900/sidecar, '02 TTR250, and another XS11 - this time a chain drive Period 5 race bike that may be ready to race eventually.
tripodtiger


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I had to wander around town, make some calls, to find the bango bolts. Two shown 'in stock' but currently MIA. So they were added to the order.
I had a sqiz on the net. I could get the bango bolts at $8.08 each. That'll do, pig! Checkout...$30 postage. yeah, nah.


Might try and find a generic 12mm hose that I can fit. Just run it up and across the frame, then back down. Estimated $150 to make a short custom one. That's UK 3.50, I think.

Fingers crossed one of the bolt shops will have the blanking bolt, even if I have to cut it down.





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In the Riverina.

'73 RD250, '80 XS1100, '81 RD373LC, '96 Tiger 900/sidecar, '02 TTR250, and another XS11 - this time a chain drive Period 5 race bike that may be ready to race eventually.
TTRfan


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Should be able to get one at a sensible price from eBay?



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tripodtiger


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Blanking bolt from United fasteners. No charge. I'll go back again and again.
I have to check if there is any clearance issue though, the bolt head is 19mm atf.

I've seen oil coolers, from China, on ebay. I don't want to do anything that encourages them. A DR cooler will come up one day.

Alternatively, I put it all together, flog it all off and buy this...

 

4346636444038783756.jpg

 

Comes with a load of spare parts that I could sell - tank, 17" wheels, WP forks, body panels, muffler and some other stuff.

Change is like a holiday, they say.   



-- Edited by tripodtiger on Thursday 22nd of August 2024 02:34:23 AM

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In the Riverina.

'73 RD250, '80 XS1100, '81 RD373LC, '96 Tiger 900/sidecar, '02 TTR250, and another XS11 - this time a chain drive Period 5 race bike that may be ready to race eventually.
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