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Drilling Gen2 oil filter cover to fit Gen1

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Drilling Gen2 oil filter cover to fit Gen1

PostAuthor: faffi » Fri May 11, 2018 4:44 pm

Some may recall that I fitted a Gen II oil filter cover to my Gen I clutch cover and 250 km down the road ended up with a dry top end. By chance I learned that the covers, although they fit fine, have offset outlet holes when compared.

My first fix was to fit my damaged original oil filter cover, but yesterday I drilled a second hole in the correct position on the more solid Gen II cover. First I had planned to block the original hole, but then I figured there should be no reason for going to the trouble.

Luckily, the cover has material for drilling a canal in either position (Gen I and II) and now I have both present. Rode 275 km today with zero issues.

Drillet oljefilterdeksel side.jpg


Drillet oljefilterdeksel.jpg
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Re: Drilling Gen2 oil filter cover to fit Gen1

PostAuthor: nanno » Sat May 12, 2018 5:29 am

Just as I did, many moons ago! :GJ:

Btw.: Gen III (V-star, Bulldog) covers are drilled like Gen I, but with a cool industrial look to it.
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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Re: Drilling Gen2 oil filter cover to fit Gen1

PostAuthor: faffi » Sat May 12, 2018 1:50 pm

Cool, good to know - thank you :cl:
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Re: Drilling Gen2 oil filter cover to fit Gen1

PostAuthor: Jake » Sat May 12, 2018 2:24 pm

nanno wrote:
Btw.: Gen III (V-star, Bulldog) covers are drilled like Gen I, but with a cool industrial look to it.


There doesn’t appear to have a recess cut into the bottom bolt hole for the small o ring on the BT1100. Do you think it would leak ?

The small o ring on the BT is on the outer cover.
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Re: Drilling Gen2 oil filter cover to fit Gen1

PostAuthor: Jake » Sat May 12, 2018 2:38 pm

401A767D-F828-44F8-AB78-058D794ACA8C.png
EBAE4663-54F6-4484-B2B1-5856E0CEF5DD.png

137D4928-F10C-4831-8C2B-3F606B4686FB.png
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Re: Drilling Gen2 oil filter cover to fit Gen1

PostAuthor: faffi » Sat May 12, 2018 5:52 pm

I don't think it will affect the cover since it is smooth on both the BT and stock, with the O-ring sitting in the clutch cover.
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Re: Drilling Gen2 oil filter cover to fit Gen1

PostAuthor: Jake » Sat May 12, 2018 8:28 pm

faffi wrote:I don't think it will affect the cover since it is smooth on both the BT and stock, with the O-ring sitting in the clutch cover.


You’re correct, I had a brain fart :ops:
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Re: Drilling Gen2 oil filter cover to fit Gen1

PostAuthor: nanno » Sun May 13, 2018 2:21 am

Sepp Koch has been using these for quite a while now, because as some other already found out: the stock oilfilter-covers with all their ears still in place start to become a bit more scarce.
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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1979 RD250/R5/DS7-hodgepodge (in bits)
Sex: Male

Re: Drilling Gen2 oil filter cover to fit Gen1

PostAuthor: tukes23 » Mon May 14, 2018 9:58 am

faffi wrote:Some may recall that I fitted a Gen II oil filter cover to my Gen I clutch cover and 250 km down the road ended up with a dry top end. By chance I learned that the covers, although they fit fine, have offset outlet holes when compared.

My first fix was to fit my damaged original oil filter cover, but yesterday I drilled a second hole in the correct position on the more solid Gen II cover. First I had planned to block the original hole, but then I figured there should be no reason for going to the trouble.

Luckily, the cover has material for drilling a canal in either position (Gen I and II) and now I have both present. Rode 275 km today with zero issues.

Drillet oljefilterdeksel side.jpg


Drillet oljefilterdeksel.jpg


Faffi, can you do me a favor and measure the angle difference between the 2 holes? Looks like its only about 15deg. How well does your drill hole match up to the side cover oil passage? I'm trying to work on the design for a GenII cover, but have I do not have one to work off of. If you can get me that info, i would be willing to deal on one of the first ones off the machine.
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Re: Drilling Gen2 oil filter cover to fit Gen1

PostAuthor: faffi » Mon May 14, 2018 4:17 pm

I do not have accurate tools and freehanded the hole I drilled, so no way to tell hos far off or not I got from spot on. The oil hole line up well enough through eye-balling to know I get full oil flow, but again I cannot tell for sure if it is one mm off one way or the other. Greg (member name nanno) would be in a much better position to give you the correct data you request - not only is he an engineer, he is also highly skilled and experienced.
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