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TOPIC: How to delete the oil cooler on a 82 J motor ?

How to delete the oil cooler on a 82 J motor ? 11 Jun 2019 16:47 #805550

  • kz650guy123
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I have a 1982 KZ1000 K LTD with the J motor. I would like to remove (delete) the oil cooler.
So looking at the service manual it looks like the oil outlets at the pressure sensor and end of the gallery on the side should be common.
So just as an experiment I tried putting a rubber plug on both of the cooler connections on the engine. Thinking that the oil pressure on this
motor is only 3 or so psi the plug should hold on it's own.
So I just disconnected the ignition so it wouldn't start and just ran the starter a few seconds. The plug by the oil pressure sensor popped off and shot oil
across the floor. Nothing from the side connection.
I removed the plug from the side gallery connection and tried the plug on the sensor again. The sensor side popped off again and nothing came out of the side connection.
Next I tried just connecting the two connections together with a hose. Now everything works normally.
So I guess these connections are not common to the gallery in this motor ? Seems I have to use the hose to get oil into the rest of the engine.
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How to delete the oil cooler on a 82 J motor ? 11 Jun 2019 18:38 #805557

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I bought a late model oil rizer for the oil switch. If you can use it let me know. Pics of what you have?
Steve
Z1b1000 1975 Z1b
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kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
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How to delete the oil cooler on a 82 J motor ? 12 Jun 2019 13:46 #805586

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I missed your pics after your PM. I was looking for a new post.:blush: The one I have I'll send to you for postage but chances are the PO blocked off the port going into the oil galley. (commonly done) I suggest taking it off and looking. If so remove the blockage and get a gauge kit or male threaded plug for the inspection port on the side. Yeah 3 psi is the running pressure but with these pumps it will build pressure until it blows or breaks something. (no relief valve)
Steve
Z1b1000 1975 Z1b
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How to delete the oil cooler on a 82 J motor ? 12 Jun 2019 13:56 #805587

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Looks like with what you have you're almost there. A fitting and a gauge, SCORE.
Steve


Z1b1000 1975 Z1b
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How to delete the oil cooler on a 82 J motor ? 13 Jun 2019 10:05 #805664

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So what you are saying SWest is that when the oil cooler was installed they blocked off the oil gallery from under the pressure switch
housing and rerouted that oil through the oil cooler and back to the side gallery plug ?
What would that plug look like and how do I remove it.
I can't find a picture of what under the pressure switch housing would look like normally.

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Last edit: by kz650guy123.

How to delete the oil cooler on a 82 J motor ? 13 Jun 2019 11:00 #805668

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Only way to find out is to take the riser off and look. One of our members found a plug in the riser. He was blowing out oil filter covers.
Steve
Z1b1000 1975 Z1b
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How to delete the oil cooler on a 82 J motor ? 13 Jun 2019 12:50 #805678

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If there is a plug in there Steve it would have to be part of the oil cooler installation.
This does look to be an aftermarket installation.
I guess I will have to do some searching for oil cooler install procedures.

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How to delete the oil cooler on a 82 J motor ? 13 Jun 2019 14:56 #805683

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Last edit: by SWest.

How to delete the oil cooler on a 82 J motor ? 02 Jul 2019 13:01 #806863

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Does anyone have a picture of what should be under the oil pressure switch riser ? Remember this is an 82 J motor.
Preferably one with an oil cooler.
thanks

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How to delete the oil cooler on a 82 J motor ? 05 Jul 2019 11:31 #807014

  • VTEC
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Yeah. That does not look like a healthy oil cooler setup. The OEM pressure switch adapter allows oil coming from the pump to unseat the pressure switch plunger then oil turns around and feeds the main oil galley. With your setup the oil unseats the plunger then out the added fitting, through the cooler, and re-enters at the oil pressure test port. You either have a homemade blockage in the adapter stopping flow to the main galley, or no blockage and you have slim to no oil going through the cooler due to equal pressure on both sides.

Take a look at the R1 parts diagram: www.partzilla.com/catalog/kawasaki/motor...-kz1000-r1/crankcase

The oil from the pump unseats the plunger, travels through the cooler, then back to the adapter to the main galley. That's the correct way.

Remove your adapter and see if the passage between oil pump input and main galley output is blocked. If blocked, unblock (and plug the add-on fitting hole) or replace the adapter. Then just plug the test port hole in the crankcase. A 14mm short oil pan drain plug with a crush washer is a better way to go than the OEM plastic plug.

Here's the underside of the adapter. Oil simply goes in and out the two passages with the only obstruction being the oil switch plunger.

KZ1000-K2
ZRX1100
XR400R
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Last edit: by VTEC.

How to delete the oil cooler on a 82 J motor ? 21 Jul 2019 18:30 #807948

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Thanks VTEC for the post and photo.
I guess I should have said that I would like to see a photo under the pressure riser. To see what a plug should look like.
There is some kind of plug there so the oil is forced to go through the cooler before entering the main gallery.
I just don't think that I will be needing an oil cooler in my kind of riding.
I will try to post a photo of the plug under my riser. I don't really know how to remove it.

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How to delete the oil cooler on a 82 J motor ? 21 Jul 2019 20:03 #807951

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I don't understand. Do you have the rizer off? With the plug in the galley only half the motor will get oil.
Steve
Z1b1000 1975 Z1b
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How to delete the oil cooler on a 82 J motor ? 22 Jul 2019 10:18 #807990

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Steve I've had the riser off and there is a plug there. The cooler intake hose takes off from the riser. Then the cooler outlet goes to the oil pressure test port and enters the gallery there.
I just don't know how to take out this plug.
When I take a picture of it I will take a closer look at the plug.

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How to delete the oil cooler on a 82 J motor ? 22 Jul 2019 10:45 #807991

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That oil galley goes in two directions. It feeds the lower end and tranny and feeds the top ends as well. If it is blocking the galley only one side will get oil. Is it rubber? You may have to drill it out then blow out the debris. I have long drill bits I used in my work.
Steve
www.homedepot.com/p/Bosch-3-8-in-x-18-in...it-BH2003T/204415305
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How to delete the oil cooler on a 82 J motor ? 22 Jul 2019 10:57 #807992

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Pic of the riser connection. See the plug with the threaded end coming out ? How do I remove this ?
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How to delete the oil cooler on a 82 J motor ? 22 Jul 2019 11:18 #807993

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It should just pull out. Maybe put a nut on it and pry it out.
Steve
Z1b1000 1975 Z1b
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How to delete the oil cooler on a 82 J motor ? 25 Jul 2019 09:01 #808111

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Well Steve I got that plug out. It was a piece of rubber on a bolt. Surprised that bolt didn't fall into the oil gallery.
I ordered a gallery plug for the side.
The fitting on the pressure sensor riser looks like some kind of pipe thread.
Steve that picture you posted above of the riser has a plug in it.
Do you know what that is ?
Does anyone know what size that pipe thread is ? Probably metric.
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Last edit: by kz650guy123.

How to delete the oil cooler on a 82 J motor ? 25 Jul 2019 09:39 #808113

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It's a NPT pipe thread. Take it to the hardware store and match it up. If you want the one I have just pay the shipping but I suspect it would be cheaper to buy a plug fitting. It wasn't blocking the galley? If not you should be good to go. B)
Steve
Z1b1000 1975 Z1b
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Last edit: by SWest.

How to delete the oil cooler on a 82 J motor ? 25 Jul 2019 09:41 #808114

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BTW get two O rings there or auto parts store.
Steve
Z1b1000 1975 Z1b
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How to delete the oil cooler on a 82 J motor ? 25 Jul 2019 11:25 #808118

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Are you sure it's not a metric pipe thread ? It measures 16mm x 1.5 pitch

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