GPz oil pipe modify or replace - help needed !

[GPZ592]

Hi all,

I have a question on modifying or replacing the oil pipes on my GPz 550. It's a long story, but the original pipes are too long for the replacement cooler I've fitted. its only about 15 - 20 mm I need to shorten them, but I'm looking for advice on the best way to do it.

First thought was to cut the pipe at the top end where it meets the cooler and flare the pipe ? Would a generic flaring tool from Ebay do the job or do I need something more specific as these tubes are steel, not copper/aluminium used in brake lines ? I believe the flare on the original pipes/cooler to be 45 degree ? Alternatively, can I remove the crimping holding the flexible hose part of the oil line and replace with a shorter pipe - how would I re-attach a replacement hose to the original steel pipe ?

The other alternative is to make up new pipes to replace the standard pipes using aerospace fittings & hose, but I think the standard Kawasaki oil cooler is not a AN fitting - looks more like M16 x 1.5 thread ? Any one know for sure and can I get fittings to suit ?

Thanks in advance.

Mark.

Oil pipe to cooler

Oil cooler to Pipe.jpg (81.79 KiB) Viewed 1661 times

Standard oil lines

Standard oil pipes.jpg (112.78 KiB) Viewed 1661 times

[Al]

I've used a couple of flaring tools for brake and fuel lines. They all grip the plain pipe to a length of at least and inch and a half. You dont have enough plain pipe now let alone after you cut off the existing flared end. Using one that grips a shorter length may end up with a partial flare and a gouged pipe!

If those hoses are made the same as the J ones i replaced; the crimp ferrule is silver soldered to the plain pipe first and then pipe inserted and crimp made. To get them undone you have to cut through them which destroys the ferrule.
You may be able to cut through the plain steel pipe just above each ferrule and get new pipe and ferrule crimped on but those may slide off.
A hydraulics company or even Pirtek may be able to help there.

Alternatively; cut the plain pipe above the crimps and use compression fittings and new flexi pipe. If you can get them in stealth black so much the better. I could not live with Aeroquip / Goodrich which was pink or blue in such a prominent position. I ended up with the hose ends which have a mostly concealed jubilee clip within them! That way i could flare the plain steel pipe before the crimp was tightened to stop them sliding off.

AL

[Philippe]

Hi Mark

my advice: find a company that makes or repares hydraulic oil lines, explain them what you want and I'm sure they can help you out.
Good luck!
GrtZ
Philippe

[Garry.L]

What size are the metal pipes?.... if they are 15mm OD then standard 15mm compression plumbing couplings would do a job..

https://www.bes.co.uk/compression-strai ... 5mm-17589/

[GPZ592]

I've used a couple of flaring tools for brake and fuel lines. They all grip the plain pipe to a length of at least and inch and a half. You dont have enough plain pipe now let alone after you cut off the existing flared end. Using one that grips a shorter length may end up with a partial flare and a gouged pipe!

If those hoses are made the same as the J ones i replaced; the crimp ferrule is silver soldered to the plain pipe first and then pipe inserted and crimp made. To get them undone you have to cut through them which destroys the ferrule.
You may be able to cut through the plain steel pipe just above each ferrule and get new pipe and ferrule crimped on but those may slide off.
A hydraulics company or even Pirtek may be able to help there.

Alternatively; cut the plain pipe above the crimps and use compression fittings and new flexi pipe. If you can get them in stealth black so much the better. I could not live with Aeroquip / Goodrich which was pink or blue in such a prominent position. I ended up with the hose ends which have a mostly concealed jubilee clip within them! That way i could flare the plain steel pipe before the crimp was tightened to stop them sliding off.

Thanks Al - I did think modifying the original pipes would not be that simple. I have a local Pirtek branch, so I may ask them what's possible. You can get Aeroquip/Goodridge fittings & hose in black - I have them on the P&M, but that uses an aftermarket cooler which has AN specification fittings and I believe the standard cooler uses metric.

my advice: find a company that makes or repares hydraulic oil lines, explain them what you want and I'm sure they can help you out.
Good luck!

Thanks Phillipe. We have a company called Pirtek that has many branches in the UK, so I'm going to speak to them.

What size are the metal pipes?.... if they are 15mm OD then standard 15mm compression plumbing couplings would do a job..

Thanks Gary. The O/D is 11mm, so an odd size for standard fittings ?

[Garry.L]

Thanks Gary. The O/D is 11mm, so an odd size for standard fittings ?

Don't know if it helps but those compression couplings I linked are also available in 10 &12mm. The 12mm ones would easily compress down the extra mm to give a leak free joint.