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Help ZXR Coolant Hoses

Discussion in 'Kawasaki 250cc In-line 4's' started by maelstrom, May 23, 2018.

  1. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Hi All,
    Working on silicone hose kits for ZXR's, so looking at parts list for the early models I find 4 hoses Are there any more hidden hoses that I am missing??
    Cheers
    Blair
    PartsDiagram_1989.jpg
     
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  2. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Hey Blair, That image is right, but confusing because of the layout of the lower pipes. 32150 has two pipes attached, which the diagram shows by the "C" in a circle link.

    Also, most of us tape around the 39062B hose where it rubs against the frame engine mounts. It's a pain and not the best from a manufacturing point of view. Linkin and some of the other ZXR fans might have some other ideas/issues for you.
     
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    Last edited: May 23, 2018
  3. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Thanks, well as always some issues.
    Here is the last model 1999, that I found on Megazip site.
    It has 5 hoses and some carb heater bits which I do not care about.
    PartsDiagram_1999.jpg
     
  4. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Yes, I've seen those, but I think the original image works across all ZXR cooling systems

    Hoses.jpg
     
  5. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    @Frankster If I can find out where the hose 39062B hose rubs against the frame engine mounts then I can have the tooling designed to fix that issue. I would like to do the later model without the carb heating junk as well.
     
  6. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    The return to radiator hose rubs against the engine mount (where the arrow is).

    Rubbing on Frame.jpg
     
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  7. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    So are you saying there is another hose hiding somewhere in the parts book?

    And if I make a working set for the early model that will work on all models?
     
  8. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    I'll have to take a pic with the RHS fairing on as there's little room for the hose to avoid rubbing on the frame engine mount. @Linkin can you take a pic and send it to Blair, I don't have a bike ATM. Not sure the C model fairing has the same issue as the A model.
     
  9. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    The first image you posted is correct, but the second image shows the hoses connecting to the bleed tube in a clearer way. There are 4 hoses on the ZXR cooling system. The second image shows the break in the radiator exit hose to feed the carb fuel bowl warmers. In the second image there are 5 hoses. On the A (and early C models) you don't have fuel warmers, so you may not be able to do a "one size fits all" with that hose.
     
  10. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    The safest route with that hose would be to go above the mount, provided that it does not create a high point in the hose before it reaches the radiator, otherwise bubbles can get trapped which is why that lower hose has a bleed point.
    Hoses.jpg
     
  11. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Okay I got it, C connects to C. So there are only two issues. One is the radiator inlet hose hitting the engine mount and the other is can we use the earlier model hoses on the later models, assuming you bin the carb heating bits.
     
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  12. sharky

    sharky Well-Known Member

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    I have only seen the 5 hose set-up on the A model with the carb coolers. The hose in question is the same length but split in the middle with a joiner, which then runs to the carbs & out to the head. 20180524_094327.jpg 20180524_095638.jpg 20180524_094415.jpg The other hose sits just on the rocker cover or wedged between the head & frame. 20180524_094453.jpg The carb heating is not needed so the 4 hoses would work fine,& if they really did want the heaters, a simple cut in the middle is all thats needed.
     
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  13. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Thanks @sharky. Yep, no carb heating stuff will be available.
    The other issue I am thinking about is the bleed point. Some of those joints rust badly. I had a stainless version made up for @GreyImport at one stage.
    BleedPoint.jpg
    It may be possible to make the hose one piece and embed a bleed point into the hose.
     
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  14. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Will there be different colours available? An orange set would be awesome for what I have planned :)
     
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  15. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    The ZXR air bleed joint is bolted to the engine. I'll upload a pic or @sharky might have one showing it's location when the LHS fairing is in place. Also, @sharky running that image of the radiator return hose doesn't look right. Squashing it on the inside of the frame is in the throttle area of the carbs. Anyone else have any images/thoughts about this?
     
  16. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    That's the issue that the manufacturer has to decide on. An orange set for your bike's colour scheme, a green set for my bike and so on. Not sure of the cost to Maelstrom to have multiple colours. Maybe a Black generic set at an entry level price point and them custom colours for a premium price might be a solution.
     
  17. sharky

    sharky Well-Known Member

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    I have only had to wedge it between the frame on one occasion to make it reach, & that was an old hose that had to be shortened at both ends. That actually moves it away from the cables further. Heres the bike I got from @kiffsta 20180524_111116.jpg 20180524_111131.jpg The A model engine mounts dont allow the room to do that. The previous owner of this bike ran the rad hose outside the frame lol. 20180524_111231.jpg
     
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  18. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Well that explains a lot. @maelstrom I guess the radiator return hose goes on the inside of the frame like Sharky said, so you're good to go. Funny, that every ZXR I've encountered runs the hose on the outside of the frame...live and learn eh!
     
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  19. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Not likely. I will advise about colour options later.
     
  20. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    For the moment I will do a standard set and then work on an embedded bleed point hose that will combine the two and eliminate the part shown above.
     

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