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Kawasaki ZX6R Supersport Radiator Extension

3/8/2020

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The Febur lower radiator extension first announced back in January 2019 has finally been installed on our Kawasaki Supersport machine, along with some shiny (and bright orange) 'kit-type' silicone hoses. The radiator extension was previously installed on a NP Motorcycles British Supersport machine, so we knew that fitment should be relatively straightforward.
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The lower radiator extension in it's former life
​The 'kit-type' water hose arrangement moves the oil filter cooler hoses into the main waterways - to reduce the water temperature circulating through that section. On the diagram below you can see the changes made.
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Stock (left) versus Kit (right) water hose routing
​Prior to fitting the radiator extension, we acquired a new (more sturdy) stone guard that matched the main radiator guard - this needed to be cut to shape, so a template was made to define our required dimensions and then cut out. Once the edges were lined we spaced the guard from the radiator using a combination of rubber pipe and cable ties.
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From a sheet of mesh...
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...we defined a template...
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...and created a bespoke guard!
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Fit to the lower radiator extension...
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...with a gap to allow deflection
​The mounting fixtures were prepared, then painted and now look like new. With all of this 'shiny newness', the radiator water expansion bottle was looking decidedly dirty, so received a thorough cleaning! With everything assembled and mounted, here are some "before and after" photos!  :-)
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In the case that we ever decide to remove/disconnect the radiator extension (e.g. due to a water leak or the bike running too cold), we have acquired some straight pipe connectors to bypass the T-pieces so that only the main radiator is used - and importantly, mean that we can continue racing.
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Bypass Pipes
Our next outing will be with the No Limits club at Oulton Park on 14th/15th August 2020, so we will be closely monitoring running temperatures during that meeting. We'll let you know what difference the changes have made!  :-)

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    Author

    David Carson Jnr,
    the Racer!

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