warrior/raptor 350 oil cooler

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| Title: Warrior oil cooling system application
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| Date: 01/30/05
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| Author: DeathShadow/Doug Maso
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this is from yfm350central.com

[Index]

+ Document overview
+ Cooling anaylysis
+ Big Bear 95' items & needed parts
+ How to
+ Hayden cooler review
+ Quick Review of the tapped case design
+ Conclusion

- Document Overview:

Well I decided to make this kind of a short tutorial & review since many questions come about regarding this topic and the hardware for it. There is a cheaper method used to do this in which you tap the clutch cover into the galley but I believe this way is more safe and just better because this design compliments and goes along with Yamaha's original cooling systems for the Big Bear and other quads. This document will go over cooling systems usable on the Warrior and will also include a product review of a specific cooler (yes there will be pictures mmm).

- Cooling analysis:

As mentioned above there are two primary ways in use as of now implemented to run an oil cooling system on the warrior. To better explain how this works it helps to get down to how each system differentiates and compares. The first system im going to address is using 95' Yamaha Big bear direct bolt on parts to get the oil out of the case and up through our custom cooling system.

For comparison here is a Yamaha Warrior blue print diagram of the Oil management system. Take note to the areas on this 2D diagram since you will be using it to compare to a big bear blue print next.

see pic 1

Now... The next image is a 95' Big Bear blue print image; look how you can apply these cooling system parts in the red box to the warrior - a direct bolt on!!

see pic 2

You will need to buy pretty much all the parts in the above red box on the chart/blueprints. These prices are quoted from an online site, its cheaper do go through your local dealer (I paid $100.00 even for everything). Here is a list of the '95 Big Bear parts you will need:

1995 Big Bear parts list:

1. Plate, Adaptor (Reference #14) - $65.00 USD
2. Plug (Reference #15) - $1.50 USD
3. Spring, Compression (Reference #16) - $1.07 USD
4. Washer, (Reference #17) - $0.21 USD
5. Circlip, (Reference #18) - $0.42 USD
6. Cover, Oil Element (Reference #19) - $22.00 USD
7. 2x Joint (Reference #20) *OPTIONAL* - $13.00 USD
8. 2x Gasket (Reference #21) - $1.65 USD
9. 2x O-Ring (Reference #22) - $2.75 USD
10. Bolt, Hex socket head (Reference #23) - $1.79 USD
11. 2x Bolt (Reference #24) - $2.67 USD

Other Needed Parts:

1. A cooler (Hayden or Permacool) - $29.00 - $39.00
2. Teflon Tape - $1.25
3. 2x 3/8" x 1/4" Barbed hose adapters - $1.60 each (Home Depot plumbing section)
4. 10' of 3/8" Oil hose (1$ a foot) - $10.00

*Your cooling kit comes with hose clamps and mounting materials.

*This entire project will cost around $155.00 for brand new parts.

Here is how you will mod your element cover to accept the hoses for the cooler. Shown here are two barbed hose fittings (3/8" x 1/4") they can be purchased at your local Home Depot in the plumbing section for $1.60 each. Behind these fittings are the copper "gaskets" shown on the previous page charts/blue prints as Ref#21. Then finally the threads should be man handled with a good amount of Teflon tape for a nice seal. The barbs are then tightened down very snugly onto the copper gasket with a deep socket and socket wrench accordingly.

see pic 3

Below is a close up view of a barbed hose fitting.

see pic 4

Although not a picture of my quad here is how the parts are applied:

see pic 5

So just to recap you simply bolt the parts on over where the oil filter cap is, securely attach oil hose to the barbed fittings, & finally we run the hose up to the cooler and attach there - That is it!

- Hayden cooler review:

The cooler that I use is a Hayden part #401 Tranny oil cooler; this cooler fits PERFECT under the hood (5" wide 11" long) of the warrior and drops the temp of the oil up to 50*F!! This cooler also does not break the bank like some people would expect; you can buy this baby from AutoZone directly or their website for $29.00!!

Here are some images of the cooler and the packaging itself:

see pic 6-8

This cooler was a great buy, it is built strong, cools VERY well, and is light.

- Quick Review of the tapped case design:

MANY MANY people sell these kits and they are really not worth it. There are lots of mixed opinions about this method but they both have there pluses and minuses; here is a pic of this type of kit:

see pic 9

As you can see the cooler in this one is much smaller and you are required to drill into the oil galley through your clutch cover. While the other method may be more expensive if you mess up your clutch cover it will cost even more; I also think it’s a good idea to cool the quad with the design Yamaha intended.

- Conclusion:

Well here is the cooler that I use - A Hayden Part #401 Tranny Oil cooler. This cooler performs very well and I noticed a very big difference with this mod on the bike; you can tell its well needed cause the cooler will get very hot sometimes so you know it is helping. So keep your clutch and crank cool, extend your engine life, and retain HP by adding a cooling system to your Warrior. Instead of using the rubber oil hoses you could go steel braided lines and make it look even more cool guy X_X!

this part posted by velociraptor350

Well we( Me and Death) have been on the hunt for a cooler that will work with the Rappy 350, and found that permacool makes a "atv oil cooler"Part #1008, which would work perfectly, the size is a little smaller then the hayden cooler, making it easier to fit. Doing some more reseach, i found permacool also sells a "compact power steering/fuel cooler" part #1007, which is the same exact cooler as the atv oil cooler, only exception is the core size, 11/32 for #1008, 3/8 for #1007. The best part was they are asking $50 bucks for the atv cooler, and $38 for the fuel cooler, and the fuel cooler flows better due to the 1/32 bigger core size. One quick call to summitracing's tech line and i got a "wtf, f**k**g permacool.............Oh sh*t, sorry for cursing" and i was sold, Here are the specs for the #1007 cooler:

see pic 10

Brand: Perma-Cool Industries, Inc.
Product Line: Perma-Cool Compact Fluid Coolers
Overall Height (in): 5
Overall Width (in): 7 1/2
Overall Thickness (in): 3/4
Cooler Construction: Tube and fin
Cooler Material: Aluminum
Inlet Size: 3/8 in.
Inlet Attachment: Hose barb
Outlet Size: 3/8 in.
Outlet Attachment: Hose barb
Number of Cooling Rows: 4
Core Height (in): 5
Core Width (in): 4 3/4
Core Thickness (in): 3/4
Cooler Finish: Natural

Be sure your performance ride is cool.

Fluid Cooler, Power Steering, Tube and Fin, Natural, Aluminum, 5 in. x 7 1/2 in. x 3/4 in., Each

Perma-Cool compact fluid coolers are designed to work with multiple automotive fluids. They're ideal for just about any application where a smaller cooler is needed. They can be used as power steering coolers, to help prevent premature power steering pump failure. Unless otherwise noted, the coolers come with hose, instructions, and mounting hardware.

As you can see its a perfect cooler for use in an atv, enough so that permacool sells the same cooler with smaller cores (less flow) specifically for ATV's.

Here's the actual cooler:

see pic 11-12