My GS1100 Oil cooler conversion with pics:

[Road_Clam]

Well I finally got all the components assembled on the oil cooler conversion. The most difficult part of the conversion was modifying the 1150 oil cooler cover to safely accept the 3/8" NPT hose barbs. I had to weld up near the bottom of the plate to effectively add some thickness material so as to allow a good, secure tap. The second issue was after welding the plate, it warped. luckily not much (about .021). I was very concerned the cover o-ring would leak. I fly cut the backside of the plate to within .005. All is fine, and NO leaks. The really cool thing about the Lockhart cooler I purchased is that it has an internal thermostat, so it will only circulate when needed. The box said for "most european twin cylinder engine bikes". It was definately kinda' a universal kit. I also had to custom fab an adapter bracket to bolt the cooler to the frame of my GS (I mounted it to the 2 M8 tapped holes for the horns). I know the hoses are criss crossed, but they can only go a certain way so as the let the thermostat work properly. Heres some pics:

 

[Guest]

Cool, man......may I ask the reason you did'nt use the provided tapped outlets...I am guessing the Lockhart cooler came with hose/fitings that were'nt compatible. I used the whole 1150 cooler/hose set-up with the 1150 cover....only needed to make an aluminum bracket to bolt it on.....no thermostat though. I have difficulty getting the oil filter out past the header pipes without unhooking the cooler hose, due to the routing...with your set-up, you will avoid that problem.

Tony.

 

[anikmankar]

Thats really cool. Always wanted to get this on my GS750E-1981. How much did it totally cost ?

Is there anything to be considered before moving ahead. Secondly, Since the Cooler so high up and is getting pushed from way down from the bottom of the airfilter - is there enough pressure to drive the oil all the way up ?

Thanks
Anik

 

[Jethro]

Clammer, I as well am wondering why you didn't use the built in oil cooler taps?

 

[Road_Clam]

I'm confused. Exactly which "taps" are you guys reffering to? When you purchase the 1150 filter cover it does NOT come "pre tapped". The 1150's oil coolers were fed through banjo style lines. The 2 large bolts thet are near the cover are whats used factory to feed the oil cooler on the 1150's.

 

[Road_Clam]

Thats really cool. Always wanted to get this on my GS750E-1981. How much did it totally cost ?

Is there anything to be considered before moving ahead. Secondly, Since the Cooler so high up and is getting pushed from way down from the bottom of the airfilter - is there enough pressure to drive the oil all the way up ?

Thanks
Anik

You are confusing me too. the "bottom of the airfilter" ??? I don't know what you are asking me.

 

[Jethro]

The 2 large bolts thet are near the cover are whats used factory to feed the oil cooler on the 1150's.

Right, that's how I hooked mine up. Does the Lockheart cooler use lines that don't work with the large banjo bolts?

 

[Road_Clam]

Right, that's how I hooked mine up. Does the Lockheart cooler use lines that don't work with the large banjo bolts?

No kidding?? I didn't know it could be done that way. The lockhart's lines are 3/8" hose. So all's I did was purchase a brass 3/8 NPT to 3/8 hose 90 degree barb. How did you connect your cooler hose? You cant buy the 1150 factory lines anymore. Did you find a used setup?

 

[Jethro]

No kidding?? I didn't know it could be done that way. The lockhart's lines are 3/8" hose. So all's I did was purchase a brass 3/8 NPT to 3/8 hose 90 degree barb. How did you connect your cooler hose? You cant buy the 1150 factory lines anymore. Did you find a used setup?

Yeah, mine is an 1150 cooler with the stock lines and bolts. I had to buy an 1150 filter cover with the smaller oil port (you know about that, right?) and good to go. The lines came with huge 21mm banjo bolts that fit right into where those two dummy bolts go. It's really clean, I just had to fabricate a rack to mount the cooler itself on.

 

[Road_Clam]

I had to buy an 1150 filter cover with the smaller oil port (you know about that, right?)

Yup. I was able to drill and tap the 1150 cover so as to accept 3/8 NPT, and not disrupt the special "1150 only" bypass cavity. I went as far as to test the flow, and about 5 seconds after I fired my engine , out came the oil flowing at a pretty good clip.

 

[Guest]

 

[Road_Clam]

Just out of curiosity, what type, and thread size are the 2 oil galley bolts that are next to the o/f cover?

 

[Guest]

Thats really cool. Always wanted to get this on my GS750E-1981. How much did it totally cost ?

Is there anything to be considered before moving ahead. Secondly, Since the Cooler so high up and is getting pushed from way down from the bottom of the airfilter - is there enough pressure to drive the oil all the way up ?

Thanks
Anik

Cost would depend on how much you end up paying for a cooler and modified oil filter cover...I don't think the 750's come stock with the provision of oil cooler outlets. Your best bet would be to look for the whole set-up on ebay or here on the GSR. Do a search...there is an Aussie member named Terry who sells the hardware to mod some of the GS'S to accept a cooler...by all accounts, his stuff is top-notch. Pressure is not an issue....the pump has sufficient pressure to send oil up to the cooler.....the 750 oil pump gears I'm running in my 1100 supposedly increase the flow by 30%.

Tony.

 

[Guest]

Just out of curiosity, what type, and thread size are the 2 oil galley bolts that are next to the o/f cover?

They are 14mm x 1.5 pitch. I can get the AN fittings that fit for 20.00 pair. The same as that is on my bike in the pic above if anyone wants them.

 

[topher1556]

They are 14mm x 1.5 pitch. I can get the AN fittings that fit for 20.00 pair. The same as that is on my bike in the pic above if anyone wants them.

Is there a way to use less expensive line (I don't need to dress mine up, I just want it reliable and cool )? I also plan on installing a thermostat in line to the cooler, could this be done with hoses like yours?

 

[Guest]

braided line isn't for dress up, its for durability. Threaded fittings are far superior to push on though with the low presure push on will work.

Thermostate? why do you want to do that?

 

[topher1556]

braided line isn't for dress up, its for durability. Threaded fittings are far superior to push on though with the low presure push on will work.

Thermostate? why do you want to do that?

I understand that braided lines are for durability, but with the low pressure these bikes make, I'd rather save the cash (how much wear is a cooler line going to experience anyways?). I have a 26yr old bike that just needs some maintenance to get it back up to date. It's going to be my daily rider, so I want to prevent as many problems as possible. It's not nearly as nice as yours (katman) so looks aren't all that important right now.

And the oil thermostat is so that the oil gets properly warmed up, and in cooler weather doesn't keep the engine from running on the cold side.

So, here are my real questions:

I have a selection of coolers to use...1 1150 stock cooler, a universal lockhart cooler, and another cooler from an unknown origin (although I know it's a nippendenso unit). Which should I use? and how much will I have in the lines (if I go braided) as well as connectors? Two of the coolers (the 1150, and the 'denso) use banjo bolts at the cooler side...could these be replace with a screw in 3/8" or other type of adapter instead of trying to make lines to work? Or would I be better off just using the lockhart, and slapping it on? No matter what I'm going to have to figure out lines/connections, I just know I'm gonna need help :-].

Ugh!

 

[Jethro]

Any lines you use should be protected. My stock 1150 cooler has standard high temp plastic hose, but it is protected in a kevlar type of braid. The cooler lines are right behind the header pipes (hot, HOT) and being in front of the engine are suspect to road debris and such hitting them. Also, the braid protects the junction of the fitting and the hose. Oil lines are not something you want to cheap on, if one get's a tear or a hole and sprays oil all over your rear tire you are in a bad way. Even if you don't crash, you are stranded, and if you don't realize you are leaking oil, you will see the oil light come on about .000000832 seconds before your engine sezies.

If you use the stock cooler you can use the stock lines and the fittings on either side of the oil filter cover. That's what I would suggest.

 

[Tom MLC]

I'd like to jump in on this thread. I'm also in the process of installing an oil cooler on my '80 GS1100E. I picked up a used Lockhart on ebay. It has a built in thermostat. There is a number stamped on the top, but it's at the house, so I can't tell you what it is right now. It has barbs for the hoses, and would require cutting & braising to replace with any type of threaded fitting.

I mounted the cooler with the fittings on the top, using the two 8MM female holes on the front of the frame. Looks like it was made to fit there. No modification necessary.

I was going to use the two fittings beside the oil filter cover. In fact, I bought a 1150 oil cooler cover on ebay. Then I heard through the GSR about Terry's adapter. I decided to go that way. I haven't installed his unit yet, but it looks terrific. Nice craftsmanship. It will replace the oil pressure sensor plate below the cam tensioner. Comes with all hardware for mounting, including a gasket, and barbed fittings for oil in & out. With Terry's adapter, and the oil cooler mounted "upside down" I plan to route my lines (steel braided push on - with pinch clamps) through the frame and over the top of the motor like renobruce did.

I should be finished this week (Man, I'm need to ride this weekend). I can post a few pics after I'm done. Renobruce has the pics of his setup posted, too.

Any thoughts from more experienced GS'ers? You guys are the GURU's.

 

[AOD]

They are 14mm x 1.5 pitch. I can get the AN fittings that fit for 20.00 pair. The same as that is on my bike in the pic above if anyone wants them.

Katman, I'd be interested in the AN fittings that fit the block. I rather not go back to the banjo fittings if possible. I removed a stock 1150 cooler from my 1100 because I didn't have the 1150 oil filter cover and I believe it leaked slightly onto the exhaust.

If I could replace the hoses on the stock cooler with fittings and such, I'd consider putting it back on.

~Adam