coolant connection fix for those not in warranty

Anything to do with the 1200 Corsaro series
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twisty
Posts: 352
Joined: 05 Jul 2008 16:49

coolant connection fix for those not in warranty

Post by twisty »

the coolant spigot , the one without a flange, the one the hose keeps popping off at the water pump , offside ,due to no flange being present.

A 28mm brass compression olive fits with about a 1mm clearance. It would be possible to permanently fit it either by using something like epoxy, jbweld or similar and as a backup , then drill and pin the olive with a brass pin and flush off.

if you wanted a really tight fit cut the 28mm olive right through at one point only ,before applying the epoxy. Clamp until epoxy sets and then pin and cut off excess both ends. A light file and that's it. 15mm solid brass pins about £1 off ebay or a hardware shop, must be brass otherwise it will corrode.
Image
the olive is that good a fit i just needed a bit of insulation tape pinched in one end of the spigot to hold it while i took the pic
Image
IMG]http://i840.photobucket.com/albums/zz32 ... CF1341.jpg[/IMG]
use a normal size stainless hose clip about 9mm otherwise a larger clip will ride over the olive
Because the olive is to form a flange you want it at the end of the spigot, otherwise it would have been possible to use a 28mm nut on the spigot, then the olive and connect a 28mm female fitting to tighten the olive and that would be ok.
The ideal solution is a cv boot clip as its narrow and can be tightened up as it's designed to fix rubber to metal.
Its slim, very thin.
http://cgi.ebay.co.uk/CVJ-Boot-Clips-5- ... 1e58840e44
Just need a tool to tighten them up and problem solved

Then you would need to cut the brass compression nut off so that you are left just with the olive. The other problem doing it this way is the olive would be about 6mm up the spigot and not at the end.
see example picture


ImagePersonally i'm just going to jbweld and pin twice, dress any burrs off and bobs your uncle. If you've seen a compression plumbing fitting you'll know what i'm talking about.
20mins work and your done.

Obviously clean and roughen the spigot before fitting.
Image

The rad hose end will probably need heated (put in a cup of boiled water)to allow it to now stretch over the flange formed by the olive. Replace that cheap crappy hose clip with a better quality one.
Image
i'll post a picture later with the olive slipped on the spigot as a picure tells a thousand words.

problem solved :wink:
cost ,
olive, peanuts
glue and pin, say fiver
i've got four spare olives if any one wants one or you'll get them in any plumbers merchant , b and q etc

Just a footnote. The olives sometimes come in two types. The very smooth one like the large photo and a more stepped one like the photo of the one fixed on a pipe. I'd prefer to go with the stepped olive rather than the smooth one, but it depends what's available. Since we're looking to make a "flange", with hindsight don't cut the olive fill the gap between the spigot and olive with the epoxy as it gives more resistance to "pull off" once pinned.

UPDATE
Olive fits fine, hose goes on with some saliva as lubricant. Problem! can't slip hose clip up hose as it's now tight at the back of the spigot against the engine casing.

A stainless cable tie works fine as it is very thin and the right width about 6mm. Getting it tight without slipping round the hose is a problem.

In the meantime i've got my brother to remove the olive (damaged my hand)and fit a stainless hose clip clamp 20mm wide 31-34mm size with a hex bolt for doing up. Sturdy bit of stuff.

For the olive to work it needs a really slim in width and slim in thickness hoseclip which can be fed tail first after the hose is slipped over the olive.
The roller bearing stainless cable ties don't have sufficient purchase to clamp up without slipping off the hose or damaging the roller calp on the tie.

The best bet would be these cv j clips if you get the tool to tighten them with. They are designed to clamp rubber boots to cv joints so are ideal, slim and narrow.
Image
CVJ Boot Clips 5 Off 32mm dia' x 7mm wide Galvanised

i think these ones are better as they are stainless
Image
£2.50 post free ebay
bay.co.uk/CV-BOOT-CLIP-19-40MM-STAINLESS-STEEL-BRAND-NEW-PACK-4-/370411256810?cmd=ViewItem&pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item563e3b3bea
not sure if the 34mm size is better as the exhaust clamp ive used as a temp or permanent solution was a 31 to 34mm, a beast of a thing.
Imagewill let you know

footnote

i see in the benelli tnt workshop manual which is available free online that the radiator filler cap is the same as the morini
Last edited by twisty on 21 Aug 2010 19:59, edited 16 times in total.
DaveH
Posts: 113
Joined: 22 Apr 2010 22:07

Re: coolant connection fix

Post by DaveH »

Good post - thanks for sharing

Dave H
Dave H


Ducati Multistrada 1200S DVT :)
Moto Morini Corsaro 1200 :lol:
Beta RR300 :mrgreen:
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Beveldrive
Posts: 64
Joined: 07 Mar 2010 02:27
Location: Loganholme, Queensland, Australia.

Re: coolant connection fix

Post by Beveldrive »

Thanks Twisty, you're a genius!
Bondo
Posts: 16
Joined: 20 Feb 2010 23:08

Re: coolant connection fix for those not in warranty

Post by Bondo »

Thanks for the interesting Post.

I have a 91/2 thats only done 500 miles so far. I'm assuming this problem exists for my engine as well. Is there any time frame that it appears to be happening, such as around three years or just random?

Any info appreciated, thanks,
Bondo
twisty
Posts: 352
Joined: 05 Jul 2008 16:49

Re: coolant connection fix for those not in warranty

Post by twisty »

mine popped off whilst idling in the garage. Couldn't believe my eyes as i was just thinking to myself i've never had that problem just the poor other buggers.

i hate to think what would happen on the road, one fried engine if you don't notice the coolant gone before it's too late.

Seems to be that as the radiator hose gets warm it becomes thinner and more pliable and you can pull the hose off, or a build up of internal pressure as the temp rises.

luckily i just switched the bike off within seconds , when the hose was cool it was a tight fit to put it back on, so it lulls you into a false sense of security. Garage floor steaming with coolant but no harm done.

Think of it this way, its less than a tenner to fix. If you were blasting along , how often do you look down at the engine , never i bet. How would you know it had gone unless you're sitting in traffic and can smell coolant.

Personally i wouldn't ride the bike without fixing it or putting a cable tie round the hose in front of the clip and then fixing it back to the frame to stop pull off .
Bet you've now had a good look at the factory clip, had a good prod around , looks okay, hose is tight nothing to worry about. :roll: I did that when i read all those old posts. Never happen to me , my rad hose looks fine.
well i'd carry a spare hose clip if i were you ,as you'll never tighten up the factory item at the side of the road.
oh and remember a kettle to boil the water to refill the rad if you do become stranded. :mrgreen:
random
Posts: 16
Joined: 09 Jun 2024 09:51
Location: Trnava, Slovakia

Re: coolant connection fix for those not in warranty

Post by random »

Hi,
I changed coolant today and noticed this: there is a small groove on spigot. And this click-clip on the hose.


I read some topics, that there were problem with coolant hose slipping of the spigot. Is this some kind of factory upgrade which should eliminate this problem? Or is necesarry to do some more upgrade? I made only 2000km since I bought it, but never noticed any troble with this, any leakage or something...
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corsaro chris
Posts: 1177
Joined: 13 Jul 2006 21:28
Location: Berks, UK

Re: coolant connection fix for those not in warranty

Post by corsaro chris »

The factory did an upgrade sometime between 2009 and 2013; my first Granpasso (2009 model) had the hose come loose in 2010 and dumped coolant all over a road outside Croydon, my second (a 2013 model bought "as new" from the factory in 2015) had the flange as shown. The original design looked really elegant with a small clip all that was holding the hose on to the engine and I had two Corsaros that never gave any problems in over 50,000 miles (both early models, but one chopped for the GP and the second a second hand extravagance some years later...)

It'd shouldn't need any alteration, but it's always worth keeping an eye on such things - although I have heard comments from some that say it can be difficult to remove water hose pipes... And yes, the current ZZ has done 14,000 miles now and I still keep a watchful eye!

CC
"I'll use the Morini"
random
Posts: 16
Joined: 09 Jun 2024 09:51
Location: Trnava, Slovakia

Re: coolant connection fix for those not in warranty

Post by random »

So in my case I have decided to make a low collar arround the edge of that spigot. It's not around entire spigot, maybe around half of it - as from rear side it is not possible to do it properly but... anyway - as barrier for that metal tie it is enough. I used some sort of liquid metal (i don't know correct english word for it), kind of 2 component epoxy material. It should be ok even with high temperatures, it's very hard and sticks to the base material really well.
It seems quite hopeful for me, let's face the real life this season and then check it again next winter.
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