Oil cooler kit installation - New product from Xj4Ever

At the recent CNYCC, one person had the new Oil Cooler Kit from xj4Ever installed onto his bike. The kit was installed on lightcs1776's xj750 Maxim follow along!

The recipient bike is about to have the oil drained, as we're changing that , too


The kit from Len


adapter plate and o-ring


Put the o- ring on, just like you do with the filter



The hoses come connected already, and all you do is install mounting plate where the. Filter would normally go, and install the center bolt as shown.

 

Now, the filter will be replaced


And installed just as it normally is


This mounting bracket .....


Gets attached to this bolt.......

 

Up top, we find this lol-. This is already present on the 750's......for other models, there is a loop available. You will need to drill a couple holes (not easy position), or tack-weld it into place. It is for the top of the cooler.


This rubber grommet goes into the loop


And the tops post of the cooler goes into the grommet! Yay....we're almost done


The top hose clamp gets mounted just like the lower clamp


And the hoses are connected to the cooler. The bottom mounting bolts are installed, and the job is almost a done.
(NOTE: I would highly recommend lightly attaching the hoses to the cooler before putting the top hose clamp on, just to give you some more wiggle room. Once the hoses are in place, then tighten down the hose clamp as well as the hose fittings onto the the cooler)

EDIT: I do want to point out - on this bike we ended up using just the top clamp as the lower mounting point was seized, and we didn't want to risk snapping anything. The kit had two different mounts, but normally ther is just one......you'll have to discuss your particular bike with Len so that you get the correct bracket.----

Here's a quick comment from Len--
-----
There is only 1 clamp used, the one that grasps both hoses and gets secured to the

heads-to-jugs stud (or studs, depending on model). I included both the single-hole

and the dual-hole clamps with the set that I sent to you, since I didn’t know which bike

you would be installing the kit onto.


On non-YICS engines, you would use a single-hole clamp, since there is only a single

stud that holds the cylinder head to the jugs (at the front of the cam chain tunnel). On

YICS engines, the head-to-jugs interface uses 2 studs, and those models use the 2-hole

clamp.
-----
Hopefully that clears up any confusion.
Snug everything up

 

Here's what it looks like when it's all in place. Looks like it's belongs there. (It DOES, doesn't it!?!?).


Time to fill up with fresh oil, and go for a ride. We added a bit extra oil to account for the new system getting filled, ran it for a couple miles, and topped it off.


One happy owner, after going for a spin


This kit was donated to the CNYCC as a special surprise installation, and was to go onto this bike as a secret and as a thanks for Chris's service to our country. He only thought he was getting an oil change-----surprise!!!!!

As you install this onto your bike, you will probably not notice any change in performance.....but rest assured, the ENGINE will notice the difference!!!!!

Thank you SO MUCH, Xj4Ever, for your continued support of our XJ's, this site, and the CNYCC.

Dave Fox (and lightcs1776)

 

Very cool! Do you know if that would work ok in conjunction with the spin on filter kit?

 

Once the cooler adapter plate is on, installing the filter is no different. So, I would assume the spin-on plate would go on like normal, otherwise. I think you would have to use a shorty filter, as you might be getting pretty close to the fender then.......but you should verify that all with Len.

 

OK, I didn't know if the new plate and stud might interfere, but I guess it really shouldn't. When/if the time comes I'll check with Len. I was hoping to do the spin on conversion while I was doing all the other work if I ended up with a little extra money (lol), but that didn't end up happening, so it goes on the wish list, now with another item!

 

Nice. Been wondering about an oil cooler after seeing one on another bike. Is this kit from stock parts? (going to look at Len's catalog now)

 

Thanks Dave and lightcs1776 for the write-up and images. It really does go on easily, but of course it should since it is a factory-designed part!

Yes, the spin on conversion system merely replaces the original finned oil filter cover part, so it too is completely "bolt-on". The only bikes that might have an issues are those with aftermarket exhaust systems, if the downpipes are too close to the engine and/or if there isn't enough of a "gap" between the # 2 and #3 downpipes.

Stock exhaust systems on all XJ650 and XJ750 (air-cooled) models will experience no fitment issues, although XJ650 Maxim owners will need to add that mounting loop as you explained.

XJ550 models: no kit available (yet!).
XJ700 models: no kit available.
XJ900 models: factory kit is available.
XJ1100 models: no kit available.

All of our spin-on conversion kits are available (come with) a shorty filter, except for part number HCP1284FR, which uses a full-size filter and will present clearance issues on some models.

http://www.xj4ever.com/spinon kit v2.1.pdf


Dave, how long (how much time?) did the install of the oil cooler kit add to the oil change procedure?

 

Yes!

 

It does. I have the spin-on kit installed with the Yamaha oil cooler adapter.

 

Can you post a pic?

 

I'll try to get one this afternoon.

 

Len, I can't thank you enough for the kit, and Dave for helping me get through the installation. Although I think it took us between half an hour and 45 minutes to install, I work rather slow as motorcycles are still pretty new to me. I think I could do this again in about 30 minutes now that I have gone through it once. And I know it is making a big difference in keeping the engine cooler. That is especially nice during the really warm summer we are having up here.

 

You're very welcome!

See, you're an expert already! Anyone needing help with an install contact Lightcs1776 for experienced, dependable help!!

 

I thought oil cooler was factory issued..

 

So that means it will fit on the Seca as well?

 

I have a spin on filter and cooler on my 82' seca

 

Only the Canadian XJ650RJ Seca models came with the factory oil cooler.

 

Great Information and write up!
A much needed addition

~Ghost

 

Corporate bean counting eliminated the oil coolers for the US market.

~Ghost

 

Along with the good starter clutch setup for the first-gen Virago.

 

As requested: spin on filter (small filter) with oil cooler adapter. What looks like oil is several month's worth of road grime. There are no leaks.

From above:


Right side view through headers:


And from the right side showing how much of the filter peeks past the front of the headers:


There is room to fit a full size filter (or the factory filter and housing), but the small filter has plenty of media, and makes it easier for me to have room for my hands when changing it.

 

So, I dont need a turbo to do the oil cooler mod?

For clarity... Until now I had assumed the oil cooler & turbo were a package deal...

Reading this thread though it seems, the turbo is NOT a requirement if I want to add an oil cooler, & an 82xj650J owner can drop in this oil cooler kit without needing a turbo, correct?

My headers are stock, but a PO, modified the exhaust behind the headers & I have no cross connect. Afaik, installing a turbo (& oil cooler) proper would require an exhaust swap too...

Not bent on having a turbo, but definitely see the advantage of an oil cooler installed.

Let me know.. Thanks!

 

I don't have a turbo on the bike, so it isn't necessary, at least with the XJ750.

 

The additional heat from the turbo is the reason the 650 turbo is the only US model to not have it removed.
An oil cooler can benefit any air cooled engine. There is no requirement to be running a turbo.

~Ghost

 

Cool good to know parts are available... However, I just looked at the price for the oil cooler retrofits..... Yikes!

Don't get me wrong.. the price is probably reasonable for someone who wants to fully restore/upgrade their xj...

For me though, my bike's value/condition does not warrant such an expensive upgrade. Even if I installed this kit, the value of my bike is not likely to change as a result... Not that I'm selling, just hard to shell out when I know there's no getting it back... :/

Still tho.. glad to see Len has parts available.... in a year or so, when its time for my 50k rebuild, this kit may end up back on my list.


Tks again guys!

 

The parts come up on Ebay, but you'll have to do the refurbishing (at least new o-rings), and take care that the seller will give a refund if the cooler has a leak.

 

Len stated to me in a e-mail the turbo and the rj cooler are different. The rj cooler is a straight fit on a maxim. The turbo cooler is not.

Gary H.

 

Well, it's a straight fit but if it's a 650 Maxim, you still must add the retaining loop bracket that supports the upper mounting peg of the cooler........650 Maxim models do not have the loop bracket on their frame, and you MUST retain the upper part of the cooler to prevent vibration of the radiator and eventual failure of it.

 

I knew I should've added that ^.

Gary H.

 

Since there's two different threads on this subject, I'll copy-and-paste to keep the info consistent:

To fit the turbo cooler onto the 650 Maxim, you'll need to:

- create an adapter bracket that adapts the radiator mounting holes to the cooler mounting holes in the frame.....it's about a 4-5" drop (if I recall correctly).
- shorten the cooler lines
- install some type of cooler upper mounting holder to accept the stud on the top plate of the cooler. If you're really creative, you can create a frame of sorts that the cooler bolts to, and which has a long "arm" that reaches up and over and grabs the stud, and then this entire frame bolts to bike.

K-moe has a 750, and those bikes came with the mounting point for the stud, so his work was much less involved (the drop-down bracketry needed to hold just the lower frame of the cooler to the frame holes would be much simpler to make).

BTW, all of the above applies to all 650 Maxim models, AND, just to make things a bit more miserable, on the 1980-81 models, you'll either have to:

- lose the tach, or
- convert to a later (82-3) electronic tach

since the turbo cooler will block the passage of the tacho drive cable.

 

Pardon my confusion, so the 'regular' cooler (RJ?) will fit on an 81 XJ650 Maxim and only requires a simple loop bracket to be manufactured to secure the top?

I need either more coffee or morse sleep.

 

ANY oil cooler added to the 650 Maxim will require a loop bracket to hold the top locating stud, because the 650 Maxim did not come with that bracket already installed on the frame. ALL other XJ650 and XJ750 air-cooled models came with the loop bracket installed, whether the bike came with a cooler or not. "RJ" is the model identifier code for a North American XJ650 Seca model, it is actually referred to as a XJ650RJ model, with the "R" indicating the Seca version and the "J" indicating a 1982 model. A regular Maxim model (1982) is a XJ650J model (because "J" is the model year code for 1982), and a 1982 XJ650 Turbo bike is XJ650LJ ("L" = Turbo model and "J", as usual, indicating 1982).

So when people speak of the "RJ" cooler, they are referring to the smaller oil cooler as used on XJ650RJ (Seca) model, but it could also be referred to as an 11M cooler (XJ750 Euro models, which came with the same "small" cooler), or a 4K0 cooler (XJ650 Euro models that came with the same "small" cooler), etc.

It's easier to think of them as large (XJ650 Turbo) and small (XJ650 non-turbo and XJ750) coolers.

Visually, the Turbo (large) cooler is taller, it has more rows of cooling fines, and it has a very short (about 1" tall) stud or "peg" on the top plate. The non-Turbo (small) cooler is shorter, but has a much longer (about 4" tall) locating stud or peg............and, when you go to try and install the two different coolers onto different frames, you soon discover why the cooler and peg heights make all the difference in the world.........

P.S. you need morse sleep, we all do!

 

that looks like a wonderfully well put together kit. how much is it for all the bits? I would assume many 100s of $s?

 

Morse sleep... sleeeeep sleeeeep sleeeep wake wake wake sleeeep sleeeep sleeeep.