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Re: Oil cooled Apache RTR180
Lovely addition to the bike [MENTION=63056]Abishek94[/MENTION].Got a $5 head? Get a $5 helmet.
Because everyone who passes, isn't a martyr!
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P200NS Spares' prices - https://docs.google.com/spreadsheet/...taGd5R2c#gid=0Comment
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Re: Oil cooled Apache RTR180
Originally posted by ROHAN SPEEDOFREAK SHARMA View PostHaha ok
How many kms done?
Close to 2500km done, working well till now!Comment
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Re: Oil cooled Apache RTR180
A small update:
Another small diy done and now the engine guard/ belly pan is back on the bike.
Heated a knife and cut out slots for the oil cooler hose. Will post pics in an hour.
Next up: Spray painting the radiator grill to either grey or red!Comment
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Re: Oil cooled Apache RTR180
Bloody hell ,TVS took so long to bring a re bored Apache 200 cc bike with oil cooling .
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Does Gixxer155 engine has this feature ,as Apache it self uses Suzuki's old gen engine.
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Re: Oil cooled Apache RTR180
Originally posted by Hitesh100 View PostBloody hell ,TVS took so long to bring a re bored Apache 200 cc bike with oil cooling .
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Does Gixxer155 engine has this feature ,as Apache it self uses Suzuki's old gen engine.
Most probably the gixxer doesn't have this feature. Will check it out on my friends bike and let you know.Comment
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Re: Oil cooled Apache RTR180
A neatly done job! Coming to the banjo-union pipes,i hope you got em bended at a pipe bending shop,if done on a pipe bending machine,then the bends won't pinch/narrow.In my bike's case,i got em custom made for 100 bucksOriginally posted by Abishek94 View PostI 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.[ATTACH]201985[/ATTACH]
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
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.
Special thanks to @gixxer_junkie for clearing my doubts and queries over PM. (He has the same setup on his fiero from 2012-2013) There is a shop which specializes in hydraulic and other hoses on siddiah road and very next to the shop ,there's a pipe bending shop.So basically bought a suitable length brass banjo union and got it bent next-door and installed it myself right on the street!
When i was doing this modification,back then banjo bolts of pulsar weren't available.So i spent best part of a week finding the right TVS bolts from shops which deal with only fasteners and spent a small fortune in getting those bolts drilled on lathes ,so that they can be converted to banjo bolts.I had tried a few other combinations ,like installing the oil cooler output directly to the head etc.So i had to get quite a few double banjo bolts to be fabricated as well.Later i bought pulsar banjo bolts and they were really cheap,because i had spent about 150 bucks per bolt in getting normal bolts converted to banjo and double banjo bolts.I had gotten about 10 such bolts done,so that was the main expense for me.
All the details as to the pitch of the thread,type and as to how and where to get the banjo bolts to be done,the different kinds of options of installing the oil-cooler,that is with regard to connecting the oil cooler output etc,they were all thought out and technically helped by Mr Venugopal and now late Mr Srinivas. Mr Srinivas was working in TVS R&D and he had already told us about the new RTR 200 coming with a oil-cooler and that it will have different oil-circuit to that of Fiero/RTR. They had suggested a better method of installing the same,but it needed changing the oil circuit on Fiero/RTR,so instead is settled for the current one.The newer RTR 200 hence has this their suggested method i think.
Here i must mention that Mr Venugopal and Mr Srinivas were the ones who made me aware of the existence of this oil-cooler provision on the Suzuki fiero engine platform.They have done all kinda tuning on the fiero engine,right from the 200cc set-up to V-Twin fiero engine as well.In fact their's is the first v-twin designed and fabricated in india.Which was approved and inspected by TVS themselves and it ended up in limca book of records as well i suppose. Mr Venugopal has designed and fabricated successfully many superchargers for the fiero engine and even a direct injection,lotus based,supercharged, two stroke set-up on the same engine platform.So basically ,for them this modification was a simple enough a job. I had gone for a oil-cooler back then because of the high compression 195 cc set-up my engine was running on.So what i meant to say is that the actual credit should go to Mr Venugopal, (late)Mr Srinivas, and Mr Krishnamurthy of ZEN TVS.But not to me.Life begins, once you hit the power band !!Comment
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Wow!
I was itching to do this to my RTR...I will get this done after the fifth service. The only drawback is I have to find a good mechanic since I am not sure that I can do this myself without breaking something
Small question: now that an oil cooled Apache is out, is there by any chance the oil cooler unit fits the old RTR? I know this is too early to speculate since the bike is not on the roads yet, but was curious to know
Sent from my XT1095 using xBhp Connect mobile appComment
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Originally posted by apachefan
The pulsar 220 oil cooler and rtr 200 oil cooler look almost the same in terms of dimension and design. It could be different internally but at first look it seems to be the same.
Now coming to the oil hose, you cant use the rtr200 oil cooler hose in the 180/160 as the oil circuit is different and they are simply not compatible due to different design of union points. So if you want to fit an oil cooler on the 180/160 you will have to come up with some jugaad either by getting the hose custom made or bending the p220 hose accordingly.
So basically, you 'might' be able to use the rtr200 radiator but not the oil hose.
Originally posted by gixxer_junkie_m View PostA neatly done job! Coming to the banjo-union pipes,i hope you got em bended at a pipe bending shop,if done on a pipe bending machine,then the bends won't pinch/narrow.In my bike's case,i got em custom made for 100 bucks There is a shop which specializes in hydraulic and other hoses on siddiah road and very next to the shop ,there's a pipe bending shop.So basically bought a suitable length brass banjo union and got it bent next-door and installed it myself right on the street!
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Thank you
The research that you, Mr. Srinivasan and Mr. venugopal have done, made it easier for me to do the job on my bike!
I had a question. After installing the oil cooler, the oil quantity needed to be increased. So suppose I am currently using 1.2litres of engine oil (originally 1litre) then at every oil change, when I drain the old oil, there will be some oil which will be in the pipes of the oil cooler and wouldn't drain out with the rest of the oil. So while refilling, should I refill 1.2liters or will 1litre suffice as there is already some amount of old oil in the radiator which isn't drained?Comment
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Re: Oil cooled Apache RTR180
And the finishing touches:
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Re: Oil cooled Apache RTR180
Excellent work.:thumbup:
RIDE HARD RIDE SAFEComment
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Re: Oil cooled Apache RTR180
😊awesome work buddy. Did you notice cooler engine after the mod?
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Re: Oil cooled Apache RTR180
Originally posted by abhiiceman View Post
I dint actually measure the temperature of the engine oil, but yes the engine does 'feel' relatively cooler after riding for a considerable distance. (feel=touch)Comment
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Re: Oil cooled Apache RTR180
Nice work [MENTION=13389]gixxer_junkie_m[/MENTION] and Abishek46!Dad's Bajaj Super-1983-1989
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