Guys I'm after some help. I spent all night last night going back through the BEC forum and photo archives to see if anyone has plumbed one of these in. Now I'm more confused than ever!!

I have a rad with two connections (32mm) and the original thermostat off the ZZR1100 D, the engine and that's about it at the moment.

The Haynes Manual shows an expansion tank, but I can't see where the connection to the system is other than the breather off the thermostat housing? It must have a drain back in?

I have a pipe running from the pump round to the rad. Do i put a t-piece in this up to the bottom of a bottle? If so does the bottle have to be higher than the engine? Or at least same height?

Yours (confused) Mike

Online Kawasaki parts diagrams

Cheers Jack. That's the same diagram as the Haynes Manual. It shows an expansion tank higher than the engine with a 4mm pipe coming off the bottom of the tank going to the top of the thermostat. I assume any expansion goes up this pipe and then drains back same way.

Only problem with this arrangement is that I have the thermostat almost at the bonnet line, so I can't get the bottle higher than the outlet, so any expansion into the tank won't drain back into the system when it cools.

Cheers

Mike

As long as there's liquid in the bottle and it's sealed it should siphon back.

Peteff, how sealed? After a trip to the breakers today I now have two expansion bottles and all the pipes I think I need. One bottle is from a Capri, which has a push on cap like a washer bottle (which I could see popping off), and the other is from a Clio with a Screw Down cap which will hold pressure.

I now have parts to make either of these two expansion systems, a pressurised one or an unpressurised one. Which do you guys think would be best?

Mike
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2 articles with engine bay pics on ZZR-powered DAX Rush here 'n' here
Also, current issue of one of the kit-car mags. has a article on ZZR DAX.

If in doubt copy

Cheers Jack

Looks like a similar system to the DAX, with a pressurised bottle on the scuttle to give it height.

Cheers again.