ktm oil cooler - Polaris Riders
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post #1 of 21 (permalink) Old 08-02-2010, 06:52 PM Thread Starter
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ktm oil cooler

ok at the risk of sounding ignorant and also irritating polaris bob and guys like him who have put a lot of thought and effort into the oil cooler on rfs engines.

i have done a bit of reading about ht racing oil coolers and also racer joes and a few home made jobbers. why do all the home made ones go in from the rear filter compartment and then back into the same spot. all the expensive ones go from the top of the valve cover down to the top of the clutch cover. it seems to me that coming from one naturally flowing out spot to a naturally flowing in spot would be better. coming from the oil filter cover and going back to the oil filter cover seems to me like it would create turbulence there. is there a check valve on the one coming back in. or does it just pick up much oil as it can and the rest flows past without going to the cooler at all.

also does the one coming from the head to the clutch cover flow up or down. it seems that it would flow up to lube the cams from down where there is plenty to pump up. that just seems like the natural spot for a cooler to me. please give me some reasons so i can make an educated decision. i am just curious which is the better way to go and why? any and all info would be greatly appreciated. thanks, leo

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post #2 of 21 (permalink) Old 08-02-2010, 06:55 PM
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If you use the line going to the top of the head you only cool a small portion of the oil. The rear filter will cool all the oil going through the pumps. the oil splits after the rear filter, it goes to the head, the crankcase, and the transmission. The oil is stored in the transmission and is dry sumped out of the crank case. This is one reason why the oil level is hard to get. The oil wuill seep back into the crankcase over time.

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post #3 of 21 (permalink) Old 08-02-2010, 06:59 PM
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Don't waste your time with the head supply line. That's MAYBE 20% of the total oil flow. The rest goes through the filters. There is no turbulence or anything. The adapters divide where the filter normally would so it is forced to go through the cooler. It basically comes from the first filter, to the cooler, then to the tranny.

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post #4 of 21 (permalink) Old 08-02-2010, 07:00 PM Thread Starter
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thanks that is the info i cannot find anywhere but here. so these more expensive ones are quite a bit less effective then the new style coming from the rear oil filter case. how about the in and out of the same spot?

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post #5 of 21 (permalink) Old 08-02-2010, 07:12 PM
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The more expensive ones you are finding are meant for bikes. Since they have a lot smaller area to work with, they usually have to resort to that head supply line.

The adapters actually go in and out of different spots. There is basically a tube that extends to the rear of the filter cage so it separates the oil coming in to where the filter should be and the oil returning from the cooler. Even though the fittings are close together, they go to different areas. A picture would help a ton but I was asked not to post the back side of the cooler.

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post #6 of 21 (permalink) Old 08-02-2010, 07:25 PM
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Its basically making a loop through the cooler, and being dumped right back in where it was when the filter was in there.
Instead of being pumped into the paper filter, its pumped into the in line of your oil cooler, and then is returned to the same place the oil filter drained into. In general terms, I'm sure Bob can shed some light on the specifics.

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post #7 of 21 (permalink) Old 08-02-2010, 07:34 PM Thread Starter
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i understand not giving out the secrets behind it. i don't want to just knock it off. i am just trying to be convinced of 2 things one that this style is the best out there because of design, not because of the more inexpensive setup. also that it is worth the cost to use this well thought out concept or, even if i spend more money, is there more to be desired by fine tuning my own setup. thanks for the further input.

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post #8 of 21 (permalink) Old 08-02-2010, 07:34 PM
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The line going to the head comes from the filters.

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post #9 of 21 (permalink) Old 08-02-2010, 08:07 PM
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Leo, no offense taken. If you don't know why, you will never know why its a good thing to have.


HT Racing "cooler"..$420ish .. Actually its more of a huge storage tank rather than a true cooler in my opinion. It takes its oil supply from the oil bolt that feeds the cams at the top of the head. That flow is limited because the bolt at the top of the crank case is a "jet bolt". Think of it as having a size 100 carb jet in it. So it will only flow a percentage of the total oil volume that the pumps put out. What is does do a great job at is almost doubling the total oil volume of the motor. This alone will increase the oil change intervals that the bike can see. Its a great item for those guys the dual sport their bikes and can put on huge miles in a week and dont want to be changing their oil by the camp fire out in the woods on day 3 of a 7 day ride.



Joe racer oil cooler.. $420ish.. From the looks of it, a well made product, that is more designed for a bike than a quad. But it can be made to work.

It taps into the oil system at the second oil filter an diverts it to the cooler. I was going to buy this one, but after trying to get ahold of the guy for 4 months I gave up & designed my own. I liked the fact that he has a remote billet oil filter, that allows you to keep both filters. I did not/ do not like his cooler itself. Its a single pass unit that will not cool as well as a double pass cooler will. Plus with it being long and round, packaging it in a quad is troublesome at best. I found out later how he taps into the oil flow, and I must say I was not impressed in how he does it.




Baldwin racing cooler..$420ish.. Very similar in design to my set up, he will only sell it as a complete kit. Taps into the motor in the same manner as the Joe Racer oil cooler but you loose the second filter. There are a few things I don't like about his set up, but I will leave it at that.



My cooler adapter..$150ish.. Taps into the motor at the second filter. You loose the second filter unless you want to install an in-line filter of some sort. (Very do-able if you really want too.)

The customer gets to choose which cooler they install and how much they want to spend on it. If you go with a Jagg cooler, you're still in at a price that is at least 100 bucks less than the next cooler "kit" out there.










Thoughts on loosing the second filter.

I did a lot of research on this subject before coming to a decision.


Things I found out.

1) Both of the stock KTM filters are the exact size size as far as their filter ratings go. So the second filter is a bit redundant, it really should never get very dirty if the first filter is doing it job.

2) The RFS motor is the only motor out there that has 2 oil filter screens and 2 oil filters on it.

3) Many of the best and fastest race teams out there are using one sort or another of an add on filter and loosing the second filter. It works for them.

4) I talked to Mark Baldwin, Travis Smith, & Alan Knowles and a few others on this subject. They all commented that they had never had an oil related motor failure when they had a motor running a single filter set up with an add on cooler.

5) All of the new KTM motors have all gone to a single filter set up, so you could deduce that KTM figured that it was not needed.


My final thought on the single filter set up is this. Use a quality filter & oil, change it often and you will be good to go no matter who's add on cooler you use.


I hope that helps.

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post #10 of 21 (permalink) Old 08-02-2010, 08:20 PM
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Otay. But remember all the posts where guys kept getting varying oil levels....with oil in the cooler at an elevated position to the main pool of oil, is that why some guys are having a hard time getting a good, consistantoil level reading? Are you guys adding an extra half quart of oil during the oil changes to fill the cooler and it's lines?Do you drain the cooler/lines topurge the old oil?Does Deadman still drink PBR?

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