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Ok what I want to know is where you would plumb in an aftermarket oil cooler on a KZ650 and if I would get to keep the oil pressure switch.
Thanks.

You're in Ireland and you believe you need an oil cooler on a KZ650; why? Considering that the temperature in Dublin rarely goes above 70 degrees F I suspect an oil cooler would be a mistake. (See image below.)

Considering that the high temperatures during the summer in Maryland are always above 90 degrees F and that I have put 60,000 miles on my KZ650 without an oil cooler and have experienced no problems, I believe putting an oil cooler on a KZ650 in Dublin, Ireland is a mistake unless the bike is being prepared for racing.

If you do get one be SURE to get one that is thermostat controlled or you will be running oil that is too cold to burn off condensation, and that's harmful to the engine.

The oil pressure switch should not be affected by having an oil cooler since the switch is located in the right engine case near the timing advancer.

If you are bound and determined to put an oil cooler on it you may be able to use the pieces from a GPZ 750, but check first to ensure everything will fit properly. Ed

I only put one on my bike due to the extreme high temps and possible future HP mods.
Steve

The reason I'm thinking of fitting an oil cooler is I'm planning a 3000+ trip across Europe. Some of it will be through some cold regions like the Alps but I wand to explore some cities too thats why I'm after an oil cooler. I'm thinking of using a stock GT550 one as there are lots available. Anyway where do I tap in to the oil system? Am I right to think that I get the oil after the oil pump and return it to the same place? Some pictures I've seen suggest that the oil comes from behind the cylinders and returns to the mail oil gallery under the crank. The metal fab bit of this project isn't a real problem, it's seeing how it's done.

Thanks for the replys Swest and 650Ed

I may have been wrong about the oil pressure sending unit. I noticed in the GPZ750 manual supplement that it was blocked off (see image below).

Also, please take a look at kzrider.com/forum/2-engine/595747-82-kz7...il-pan-compatibility . There's some discussion about putting an oil cooler on a KZ650. Ed

As I understand it, a 750 oil pan with the cooler port fittings will bolt onto the 650. There are some variations in the later oil pans; finding one without the oil level sensor would be appropriate for the 650. I installed such a pan and oil cooler from a GPz/750L on my 750E and it was a clean swap.

You can also buy engine port adapters so you don't need to change the oil pan.

kz650files.kz650.info/adobe/KZ650OilCooler.pdf

www.americanclassix.com/kawa_improvements.html

The photo below shows the oil pan I used on my 750. Note how there are two different bosses on this pan that are not used.

The 82 GPZ750 pan will bolt on and it has the fittings for the oil cooler. I did that swap on my KZ650. Makes for a really clean setup, looks OEM.
Why would you need an oil cooler for cold weather. The only reason I put one on mine was I installed an 810cc big bore with high compression pistons with lots of other performance mods and I live in the Desert so temps get well over 100 degrees.

Maybe he wants a oil cooler for long grades up mountains on his 3000 mile journey across Europe.
I know a oil cooler helped me out west while climbing mountain roads .. Kept my temps under control..
Just a thought
Dave

LadsThanks for your responces

650ed and Nessism It does look like the straight sump swap is the way to go (thanks for the links). Baldy 110 your oil cooler does look very OEM. Another thing is that the cooler rad itself looks very like a GT550 one (which would be easier to pick up here). Either way I'm impressed with how it looks.
Street Fighter LTD the tempature here is getting close to 30C or 86F during the day and Mr Kawasaki doesn't like it. most of the time it's not really an issue but During the summer riding through the city, Start, Stop Start Stop type riding.

Lads Thanks again for all your help. I have a plan now and this is going to be a lot easier than I thought

Cheers.

No eBay APP ID and/or Cert ID defined in Kunena configurationI'm using the same cooler/lines as baldy110. Kawasaki used those parts starting for the 1982 750R bike through 1984 (or maybe later?) on the KZ750L (700 in the USA). One of the nice things is that it's easy to mount that cooler to the frame and the lines are a direct bolt-on.

I've just been looking at my frame and if I move the horn theres a lot of space to fit the rad. I also found a GPZ 750 sump on ebay in the UK for around €40 including P+P. I also came across a rad and oil lines for a zepher 550 that looks a little shorter but deeper than the 750 one. Its cheaper too. I'll have this bike ready in no time at this rate.
Next month the wife and I are going to Manchester in the UK for a kind of dry run just to see. The real trip is going to happen in june next year. We are planning on crossing Wales and England Then a ferry to Holland. On to Germany south to Austria, over the Alps to Italy. And back through France.
Thanks again for your help.

Another quick question Guys, have any of you ever used those oil filler cap / tempature gauge things? I think the probe bit looks a little short to give a accurate reading, Are they a novelty or genuinely useful.