I have read a few threads about this and I think I have most of the connections covered off. Can you check I have this correct and advise on the connections I am not sure of. Rad is the usual Polo one.

Thermostat - top hose on rad
Oil cooler - top hose on rad
Small thermostat hose - top hose on rad
Expansion tank outlet - top hose on rad
Water pump - bottom hose on rad
Small connection on rad at top - ?
Expansion tank top hose - ?
Small hose from water pump to tee piece that goes to back of engine - ?

I think that's everything.

my 98 R1 engine is plumbed like this.

Main hose from thermostat to top of polo rad
hose from oil cooler teed into main hose from thermostat
small hose from thermostat to top of header tank (bleeds air out of the engine)
main hose to water pump from bottom of rad
small hose to pump from bottom of header tank (feeds extra water in if needed)
small hose outlet on polo rad tapped to M5 and bolt fitted for bleeding.

How i've got my running is

Outlet from expansion bottle to small T piece, that goes the back of the engine.

top of expansion bottle to the small connection on top of the rad.

water pump to botton rad.

themostat big hose mine has the little hose going into that after the themostat built into it as i have the bike hose, to top on rad with the a T peice going to the oil cooler.

i've had it all running with the fan kicking in, so i hope that all ok.







[Edited on 18/3/08 by Johneturbo]

Here's a pic of that smaller hose after the stat. thats part of the bike set up that came with it.
Rescued attachment coolent top hoses.jpg

Thermostat - top hose on rad - Yes
Oil cooler - top hose on rad - Yes
Small thermostat hose - to expansion tank outlet via T
Water pump - bottom hose on rad - Yes.
Small connection on rad at top - ? - To expantion bottle top outlet via T.
Expansion tank top hose - ? - to T as above.
Small hose from water pump to tee piece that goes to back of engine - ? loose the T and connect to throttle body thermo valve.

adrian

Thanks for the replies.

Seems there's no set way of plumbing it in as everyone seems to do something a little different. Something I cant understand though and that's why take the small pipe on the thermostat housing to the header tank? surely this is a bypass pipe for when the stat is closed and if it goes to a tee in the main thermostat hose on the bike then this should be replicated.

The only other thing to consider is where to connect the header tank in? some connect it to the bottom hose, some to the top hose and some to the small water pump hose. The header tank on the bike connects to a small hose at the top of the rad and also has an overflow pipe that hangs out the bottom of the bike, couldn't this be replicated in the car? only thing I can think of is that the bike rad has a pressure cap fitted and the Polo one hasn't so any build up of pressure would have to go back to the header tank.

Here is another diagram I found

[Edited on 18/3/08 by stuart_g]
Rescued attachment R1.jpg