In order to fit the electric water pump and under-seat radiator, the coolant hoses and fittings need to be replaced or modified.

A coolant flow diagram from the FZR400 service manual can be downloaded here.

Coolant Outlet Tube

The top coolant outlet fitted to the engine has to be removed and modified. After bead blasting some corrosion can be clearly seen.

The vent pipe needs to removed and reversed to suit the new position of the radiator.

and the damaged end needs to be cut off and a 90 degree elbow fitted.

Done! The piece that was added was cut off the intake pipe. The angle is actually tighter than 90 degrees to get a clear run back to the radiator. Finished with zinc plating.

Coolant Inlet Tube

Rather than trying to make a new inlet tube it was easier to just buy a second-hand item from an FZR600 and cut it up as required. The original Yamaha part also has the bead at the end of the pipe that helps to retain the coolant hose.

Cut the pieces to the appropriate length and weld together.

Test fit the assembly

The finished piece zinc plated.