Re: Oil cooled Apache RTR180

Thread Approved

Waiting for the rest. If you have done it yourself, let me know, i will shift it to the DIY section. Provided you have pictures and text of how someone else can do it as well.

Cheers

Re: Oil cooled Apache RTR180

Correct me if i am wrong but as far as i know. Oil cooled bikes use their oils to cool the engine components apart from using oil to lubricate. Thats the reason they need oil cooler, to dissipate extra heat.
A non oil cooled engine doesn't use its oil to cool its internals so they don't need an oil cooler
Wouldn't such a mod reduce the oil temprature and hence its lubricating property on a non oil cooled bike?

Re: Oil cooled Apache RTR180

Good DIY. How did you channel the pipes from oil pump and ensure the circulation happens through the cooler?

Re: Oil cooled Apache RTR180

Good mod! Better pics required .
All engines are oil cooled , if they require more cooling efficiency then they can be cooled via water circulation or cooling the oil itself.
All engine oils have operating range of temperature , its always desirable to have lowest oil temp ( within the oil spec range)
Hotter the oil gets , lower is its viscosity and poor is its lubrication.


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Re: Oil cooled Apache RTR180

Very good set up Abhishek 👍. [MENTION=51699]dustom_99[/MENTION] small correction, viscosity increases with temperature but lubrication may be poor, not sure about it.

Re: Oil cooled Apache RTR180




Not even worth a Google search. Isn't it practical observation that hotter the liquid gets less viscous they become.
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Re: Oil cooled Apache RTR180

[MENTION=51699]dustom_99[/MENTION], Sorry.. You are right👍

Re: Oil cooled Apache RTR180

Thank you for the approval @The Monk I bought the parts myself and got the required welding done at a fabrication workshop, does this qualify for a diy?

Details about the Oil cooler and the fitment:
An oil cooler basically acts as a small radiator that helps keep an engine cool by keeping the oil supply at a Constant temperature. Cooled oil helps keep the engine running smoothly, particularly during gear changes in very hot weather or on long-haul trips when things might otherwise have a tendency to overheat and break down.

It so happens that when Suzuki developed the fiero, they gave a provision in the crankcase to fit an oil cooler i.e there is an outlet provided from the oil pump to the oil
cooler and an inlet to the oil reservoir from the oil cooler, both of which are otherwise plugged (using nuts) at the factory.
Since the Apache series is based on the fiero platform, the same crankcase design is carried over and hence there is a provision to install an oil cooler in the apache series as well. There were no mods (cutting, welding etc) done to the engine, it is a plug and play fixture as far as the engine is concerned.
The only work which will have to be done is fixing the oil cooler unit under the fuel tank and bending the oil hose.


The parts required along with the quantity and price are as follows:

1 unit of Pulsar 220 oil cooler (radiator) Rs 1300
2 units of Pulsar 220 oil cooler Hose (1 for inlet and 1 for outlet) Rs 600 for both
2 units of Banjo bolts from p220 oil cooler assembly (to fasten the hose on the engine side)
4 units of brass washers (2 for each banjo bolt)
4 units of suitable nuts to fasten the hose to the radiator
2 units of gaskets to fasten the hose on the radiator side

Step1:
Initially, I got the radiator bolted directly on to the clamp meant for the horn on the apache without any welding, but this setup was faulty as the radiator would touch the mudguard whenever the suspension was compressed beyond a point. To resolve this issue, I had to get the horn clamps removed, move it about 1 inch backwards and then weld it on to the chassis. With a good welder/fabricator this shouldn't be a problem.




Step 2:
Next it was time to fit the hose. Since the hose is from a p220, it is tailor made to fit the p220 and cannot be used on the apache without modification (read: heating and bending). I got the hose bent by checking the length requirements and made sure that it did not touch the exhaust bend pipe at any point. It is important to check if the oil passage within the hose is intact even after heating and bending it. This was done by passing compressed air through the hose and checking the air output at the other end.

Step 3:
Once the hose was bent and the radiator was installed, the connections had to be made. It is fairly simple to connect the hose to the radiator, but be sure to use the particular gasket. On the engine side, Banjo bolts are used to connect the hose along with brass washers. The banjo bolts used for fastening brake lines in our bikes are shorter in length, therefore it is safer to buy the p220 oil cooler banjo bolts from the service centre itself which are about half an inch longer than the regular banjo bolts used in brake lines.



Step 4:
Oil cooler successfully installed
precaution: Since the p220’s thermostat cannot be installed on the apache, warming up the engine for 2-3 minutes after every cold start is even more important.

1 part which will have to sacrificed is the engine belly pan i.e it can no longer be used as it comes in the way of the oil hose. Now it is sitting at home.
Another small work that has to be carried out is to bolt the horn onto the crash guard as shown in pic below.
Total cost of this setup including the labor work (fabrication) is Rs 2800 approx.


Special thanks to @gixxer_junkie for clearing my doubts and queries over PM. (He has the same setup on his fiero from 2012-2013)

I will update the improvements I observe due to the oil cooler (if any) in the next post after I clock enough kilometers on this setup in city and highways.

Please feel free to ask any questions!

Re: Oil cooled Apache RTR180

Well done! Half the battle is knowing your vehicle.
Information that the engine already has a provision for oil cooler is the key here. Good DIY!

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Re: Oil cooled Apache RTR180

Thank you!

Re: Oil cooled Apache RTR180

Nope, oil is not just a 'lubricant', it is also a cooling medium. The fact is that irrespective what is the cooling setup of your bike i.e air cooled or liquid cooled, 70 to 75% of the cooling of the engine is done by oil. Oil coats the surfaces and absorbs heat. It is then taken away & dumped into the oil sump. As the heated oil is taken away it is replaced by relatively cooler oil & the process continues.

Putting a oil radiator extends the engine oil's life & provides for a more stable operating oil temperature. However, that is only half the story.

An actual oil cooled engine like the GSXR 750 SACS (Suzuki Advanced Cooling System) has more than just a radiator. The GSXR 750 had an awesome air cooled engine with a huge curved oil radiator. More than the radiator, it was the internal setup that was important. Suzuki designed the system to spray high pressure jets of oil under the crown of the pistons to carry away the heat from the pistons. Suzuki also designed a 2 chamber oil pump for the bike. One side would provide high pressure oil to the piston crowns & head. The other side would provide low pressure, high volume oil to the crank journals & cylinder walls. This setup allowed Suzuki to make a bike that was lighter than its competitors while making almost as much power as them.

However, such a system is not without its cons. Such a system faces problems such as resistance to oil, which scavenges power (also called oil windage).

Re: Oil cooled Apache RTR180

I had read somewhere that merc benz sl300 had a big oil cooler due to which its oil never actually reached its optimum temperature. I was wondering if same was going to be the case here. Thanks for clarification

Re: Oil cooled Apache RTR180

Why not use the cooler in the avenger? Its cheaper without the sensor (although by only 150rs [emoji14]) we can't use the sensor anyway! My friend did this too and i am on the way so i have a little idea.

Re: Oil cooled Apache RTR180


Yes that too can be done, but I wasn't aware that the avenger doesn't have a thermostat till I noticed it 2-3days ago!