FZRSupport: the FZROnline Archive

Hi,

i was wondering which radiators did you use for this conversion and how did you mount them ?
the FZR 600 radiator wont fit and the YZF radiator needs custom mounting plates or something like that
heres a picture of how the bike looks right now
http://img338.imageshack.us/img338/2081/testtpv.jpg

Use the YZF rad. It is a little bigger than the FZR. Just bend up some 1/2"x1/16" stainless steel bar t make the bracket.

While it is a 600 frame, same concept.

When I was in Atlanta with BMiller and Cad600, they were both using YZF600 Radiators (BMiler had a FZR400 Frame, YZF600 Motor; Cad600 a FZR600 frame with YZF600 Motor). Custom brackets do have to be made, though they were made with some aluminum flat bar bought at Home Depot or Lowe's in about 15-20 minutes by Cad600. He might be able to offer more insight.

Another option is some years of Kawasaki ZX7 Radiator. It's bigger, curved, and uses the same flow pattern as the FZR and YZF; but would definitely need custom mounting brackets.

YEP wut he said

thanks but im looking for a more cleaner solution because the bike will be naked/without fairings
i thought about maybe welding some mounts to the YZF radiator so it can be mounted on the original mountingspots but i also fear that the material is to thin for welding

Most radiator material is too thin for welding, and with some radiators you don't know what type of material you're working with until the radiator is stripped of all paint, so you could be trying to attach brackets to aluminum, brass, copper, or even steel.

Almost all work done to radiators is done by brazing, which is similar to soldering. Any radiator shop should be able to braze stuff to the radiator, so if you still had the FZR radiator laying around and measured things just right, you could have them remove the mounting brackets from the YZF Radiator and attach the FZR brackets for a simple, bolt-on installation. You would need to have everything measured and documented just right before you took it to the shop, though.

That's what I though about doing with the 1990 ZX7 Radiator I have sitting on the shelf at home, anyway.

The FZR rad would be the simplest if you want a clean factory look. But the plumbing because of the YZF engine makes it difficult. The YZF rad is the better choice because of it's slightly larger size and the coolant tubing is available from Yamaha still.

If you were to paint the brackets flat black, they would almost disappear. Another way to do it is to fabricate some small brackets then you drill and rivet directly to the side of the rad. This has been done many times by others. You just want to be very careful when you drill into the side so you don't go too deep. You would also want to use a sealant and possible an adhesive to help seal and hold the bracket into place. Doing this would allow you to mount it more like the FZR rad.

One other option is to look at an old CBR600F2 rad. I don't know how it mounts, but it use to be a common swap.

i think i will try to find someone who can braze me some mounts to the YZF radiator
the FZR radiator wont fit because the taller engine is in the way, you cant get the rubberthing into the hole because the radiator hits the cylinderhead

Does stock bodywork fit over the YZF radiator?

Flo wrote:you cant get the rubberthing into the hole

Use some lube.

pefrey wrote:Does stock bodywork fit over the YZF radiator?

Yes it does. I have one on mine with the stock side fairings.

Flo wrote:the FZR radiator wont fit because the taller engine is in the way, you cant get the rubberthing into the hole because the radiator hits the cylinderhead

It will not fit into the same place as the FZR rad will. I didn't even bother trying to use the little locating tab on the top as the radiator is too tall and hits the cylinder head (as you just found out). Instead, locate it forward and down a little.

the_finch wrote:Most radiator material is too thin for welding, and with some radiators you don't know what type of material you're working with until the radiator is stripped of all paint, so you could be trying to attach brackets to aluminum, brass, copper, or even steel.

Almost all work done to radiators is done by brazing, which is similar to soldering. Any radiator shop should be able to braze stuff to the radiator, so if you still had the FZR radiator laying around and measured things just right, you could have them remove the mounting brackets from the YZF Radiator and attach the FZR brackets for a simple, bolt-on installation. You would need to have everything measured and documented just right before you took it to the shop, though.

That's what I though about doing with the 1990 ZX7 Radiator I have sitting on the shelf at home, anyway.

I had to repair a leak in the rad that was on my bike when I got it. It was a crack at the base of the lower outlet tube. I got the welder at the shop I worked at to run a bead with the TIG. The side tanks are aluminum. If you know a skilled welder, its not a big deal. The repair held like a champ for a year until I pulled it off for the rebuild. I dotn think welding some new tabs on woudl be a big deal so long as the welder knows what hes doing. Granted my welder used to weld missle housings for the gov't, so he's pretty good.

i have the same setup (fzr400 with yzf 600 motor) that i just bought recently but it still has the stock 400 rad and no fan. how quickyl do you think this would overheat under normal driving conditions? or is it not really an issue exceptfor long rides?

Jamezzz wrote:i have the same setup (fzr400 with yzf 600 motor) that i just bought recently but it still has the stock 400 rad and no fan. how quickyl do you think this would overheat under normal driving conditions? or is it not really an issue exceptfor long rides?

Long rides shouldn't be the issue, but idling could result in a bad situation. The FZR400/600 radiators are totally inadequate.

Sitting at a Track Day before we hit the track, my FZR600 was overheating after 4 minutes idling. That was distilled water and water wetter...