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 Post subject: Coolant Reservoir/Tank and Radiator hose modification:
PostPosted: Tue Aug 28, 2007 6:06 pm 
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Joined: Wed Sep 06, 2006 12:00 am
Posts: 101
Location: USA
model: 907 I.E.
year: 1991
The problem with the original Paso cooling system design is that the polyethylene tank is under pressure and in time splits at the seam from thermal cycling. There is also an availability problem with the tank itself, as well as the unique Y radiator hose that it connects to. Most bikes incorporate a radiator cap either on the radiator on in the upper radiator hose. The coolant tanks in these designs merely serve to keep air out of the system while allowing the coolant a place to expand. Their overflow is vented to the air and they hold no pressure. The Paso can be modified to work in this fashion with a few changes. First, locate a radiator filler neck from a 95-98 Honda CBR 600F3 or CBR 600SE. You can also use the radiator cap and short radiator hose that attaches to the bottom of this filler. Second, cut the Paso upper radiator hose just before the vertical bend and Y going to the coolant tank (see figure). Third mount the new filler neck just above the radiator with a short piece of radiator hose. The cut radiator hose will now attach to the 90 degree portion of the filler. Route a 3/16” overflow tube from the filler neck to the bottom of the coolant recovery tank. The larger opening in the coolant recovery tank can either be adapted using hose and fittings or the inside can be tapped for a ¼” NPT thread if in good shape. Put a hose clamp on the outside of the exit pipe to keep the plastic from splitting, file it to 7/16”, then carefully thread it internally. A ¼” NPT to 3/16” barbed fitting can be installed with automotive Goop and the 3/16” hose attached to it. Now remove the rubber gasket from the coolant tank cap and cut a slit that allows it to vent thru the center valve in the cap. Add antifreeze thru the filler neck, install the radiator cap, fill the coolant tank, and you’re done! Because your coolant tank no longer needs to hold pressure, it can be repaired with Goop if it as leaking prior to this modification. Since my upper radiator hose was in good shape where trimmed, I did not search for a pre-formed alternate source for it. Straight 1” heater hose may work or the hoses from the Honda filler neck, please pass along suggestions!
http://mysite.verizon.net/anigro754/id1.html


Last edited by Shelboss on Sat Nov 01, 2008 2:07 am, edited 1 time in total.

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 Post subject:
PostPosted: Thu Aug 30, 2007 12:26 am 
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paso grand pooh-bah

Joined: Thu Jun 21, 2007 12:00 am
Posts: 1471
Location: Gothenburg, SWEDEN
model: 907 I.E.
year: 1991
Thx f sharing! :thumbup:

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 Post subject: Re: Coolant Reservoir/Tank and Radiator hose modification:
PostPosted: Tue Oct 28, 2008 4:38 pm 
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paso grand pooh-bah
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Joined: Mon Jul 19, 2004 12:00 am
Posts: 1714
Location: Eastern Shore, MD
model: 750 Paso
year: 1988
Shellboss,

CAn you send the info on this direct to me so that we can archive it??

You pictures too??


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 Post subject: Re: Coolant Reservoir/Tank and Radiator hose modification:
PostPosted: Thu Nov 06, 2008 4:10 pm 
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Joined: Wed Sep 06, 2006 12:00 am
Posts: 101
Location: USA
model: 907 I.E.
year: 1991
Hi Jon, I sent you a PM requesting an e-mail address to send to, thanks
Art


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 Post subject: Re: Coolant Reservoir/Tank and Radiator hose modification:
PostPosted: Sat Nov 08, 2008 2:04 pm 
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paso grand pooh-bah
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Joined: Mon Jul 19, 2004 12:00 am
Posts: 1714
Location: Eastern Shore, MD
model: 750 Paso
year: 1988
Art, just send to slocumjon AT gmail .com


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 Post subject: Re: Coolant Reservoir/Tank and Radiator hose modification:
PostPosted: Fri May 08, 2009 3:19 am 
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Joined: Wed Sep 06, 2006 12:00 am
Posts: 101
Location: USA
model: 907 I.E.
year: 1991
An alternative to automotive Goop is Hot Melt glue.
If you picked up the Honda radiator cap with your filler neck, it is rated at 1.1 Bars (approximately 16 psi). To run at the lower pressure that the Paso was designed for, pick up a Stant #11227 radiator cap or equivalent at the local auto parts store.


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 Post subject: Re: Coolant Reservoir/Tank and Radiator hose modification:
PostPosted: Fri May 08, 2009 5:36 pm 
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paso grand pooh-bah
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Joined: Mon Jul 26, 2004 12:00 am
Posts: 3061
Location: Finland
It would be nice also, if those old inch measurements will changed to normal metric sizes, as metric sizes are more used in whole world and its just going to metric sizes! (Also in usa and U.K. little by little...) Ducati uses only metric units sizes in threads... :mrgreen:

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 Post subject: Re: Coolant Reservoir/Tank and Radiator hose modification:
PostPosted: Sat May 09, 2009 12:40 pm 
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paso grand pooh-bah
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Joined: Tue Dec 06, 2005 12:00 am
Posts: 3312
Location: Roma, Italia
model: 907 I.E.
year: 1992
It's not so easy.
I'm still not accostumed to think in Kw rather than in HP....
Ciao

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 Post subject: Re: Coolant Reservoir/Tank and Radiator hose modification:
PostPosted: Thu May 14, 2009 7:56 pm 
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Joined: Wed Sep 06, 2006 12:00 am
Posts: 101
Location: USA
model: 907 I.E.
year: 1991
I worked for a US company that converted to metric back in the 70's. Unfortunately, the US component suppliers never switched, so everything became a mixed bag. Even Ducati uses British Standard Pipe for their newer exhaust pipe plugs, go figure!


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 Post subject: Re: Coolant Reservoir/Tank and Radiator hose modification:
PostPosted: Fri May 15, 2009 11:45 am 
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Joined: Thu Apr 03, 2008 4:38 pm
Posts: 149
Location: Boston, MA
model: 907 I.E.
year: 1993
Shelboss wrote:
I worked for a US company that converted to metric back in the 70's. Unfortunately, the US component suppliers never switched, so everything became a mixed bag. Even Ducati uses British Standard Pipe for their newer exhaust pipe plugs, go figure!


Also for oil pressure switches, and some brake/clutch lines.

BSP is the EU standard for most hydraulic and pneumatic connections. I agree it's weird, but I guess it was originally selected for three reasons - the availability of a tapered standard, to differentiate energy carrying threaded holes from normal holes, and to appease the British, who were reluctant to join ISO.


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 Post subject: Re: Coolant Reservoir/Tank and Radiator hose modification:
PostPosted: Sun Aug 02, 2009 10:01 pm 
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Joined: Thu Feb 07, 2008 5:55 pm
Posts: 40
Location: Seattle
model: 907 I.E.
year: 1993
I just did this mod after a long run of 90+ degree days here in Seattle (WoooHoo!)

Anyway I thought I'd share my experience:

I found that I could invert the original Y-hose (top hose) and it fitted the Honda filler neck nicely.

Upside to this is that I put a bung in the original narrow neck that went to the reservoir and that sits down by the frame in a vertical position and gives me a nice point to drain coolant from the upper part of the system. It also means I can revert to standard config should I ever need to, since I didn't have to damage the stock (and hard to find) Y-hose.

Now to fix the coolant reservoir cracks with something and I'm done!

Cheers
Andrew


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 Post subject: Re: Coolant Reservoir/Tank and Radiator hose modification:
PostPosted: Mon May 25, 2015 2:28 pm 
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Joined: Thu Mar 20, 2014 11:51 pm
Posts: 8
Location: USA
model: 907 I.E.
year: 1993
guys check this out. looks like the tank can be plastic welded. Here is a video showing how. https://www.youtube.com/watch?v=k_Fkhz2G9Is


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 Post subject: Re: Coolant Reservoir/Tank and Radiator hose modification:
PostPosted: Thu May 28, 2015 10:58 pm 
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paso grand pooh-bah
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Joined: Sat Sep 03, 2005 12:00 am
Posts: 1322
Location: SF Bay Area
model: 750 Sport
year: 1990
Yup, that should work. Also can use just an old soldering iron. Just need some filler rod that is the same resin. Most likely Polyethylene, but might be polypropylene.

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1990 750 Sport x2-Rosso Blanko (900ss copy) & Nuovo Nudo (Scrambler project)
1991 907 -mostly stock
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