I used 90 degree, 3/4" brass, Pex pipe elbows and three short lengths of 3/4" silicone reinforced heater hose. The actual Kawasaki rubber pipe is 22 mm which is 7/8" but finding the 90 degree elbows in that size proved futile, for me anyhow. So using the 3/4" elbows I went and tried using regular automotive neoprene reinforced heater hose but it wouldn't fit over the shoulder roll of the t'stat and cylinder head stub pipes very easily. Next I tried the 7/8" neoprene and it was a bit too loose for my liking on the 90 degree 3/4" elbows but it would fit over the shoulder roll of the metal stub pipes.
So next I asked to try the reinforced silicone hose in a 3/4" size and because of silicone's relative soft composition it did fit over the shoulder roll and it was a tight fit on the 90 degree elbows so I went with that size.
As one can see the 3/4" silicone hose is a good fit on both the stub pipes and onto the elbows, and a fairly close location match to the new 39062-1149 hose to the right of the Frankenstein setup. I haven't used the hose clamps yet but I don't anticipate any slip off problems once the hose clamps are in place and tightened down. As an added bonus for the owners of the 94 and 95 models, the colour is matched pretty closely, LOL. For my use I will wrap the Blue with Black friction tape.
This works for both RH and LH cylinder head hoses by turning the elbows to suit, and it only takes 7 inches of hose for either side which is good as the hose up here is $13.66 CDN wholesale price per lineal foot!
For the bypass hose I used a 1/2" Pex pipe 90 degree brass elbow and regular neoprene, 1/2" heater hose available in bulk from Napa under their part # ( in Canada ), H 110. I had tried the Gates # 18076 pipe but it is actually 5/8" I.D. and the OEM is 12 MM which is 1/2".
Anyhow, just goes to show where there is a will there is a way to keep these old bikes alive and well.
Dave
