XCR cooling ??

Xcr

RS:
I ran the XCR in a 01 Gen II chassis without the thermostat. I used the Edge water bottle in the line coming out of the head and going to the brake. I had a hose that had a bend in it that was the same size as the bottle. The other side of the bottle fit the large hose that goes to the brake. This is a constant circulation set up so I just let the machine warm up well before riding to prevent cold seize. The hose routing was out of the head and into the bottle, out of the bottle into the brake, out of the brake down the right side, accross the rear cooler and in the left side. Using the stock Gen II hose out of the left side and in the crossover. Out of the cross over into the water pump.

The XCR makes lots of heat but mine cooled fine. I made sure I ran scratchers in the hard pack and no problems.

Here is a link to a photo:
http://www.snowest.com/forum/showthread.php?t=60060

Xcr

One more thing, in answer to your question about a thermostat restriction. The stock hose routing on an XCR is a 2 stage deal. When the thermostat is closed, water still circulated throught the crossover cooler. This is very much like the edge set up is. When the motor and front cooler get warm the thermostat opens to the rail and rear coolers and starts closing the front cooler off. Coolant is mixed in the water bottle to maintain a constant temp going into the motor. When it gets hot enough, the crossover cooler is shut off and the other coolers take over completely. Perhaps that is what you are trying to come up with. Look at the stock routing on a parts list and it may give you some insight. That set up had water moving all the time but I think the crossover restriction would be about the same as the smaller tube restriction that you are talking about.

If you are going with an after market in line themostat housing, I would be sure to T the lines before the thermostat so you will have constant circulation to the pump or you can even drill a hole in the thermostat so some water circulates even when it's closed. That shoiuld keep the water pump from burning up it the thermostat sticks. As you know the XCR WP is way expensive.

Cooling

As you can see on mine, my bottle is on the outlet. I don't think you need to worry about hot coolant poping the cap, it's a pressure cap and the pressure in the complete system is what would make it open. I put my bottle in the out side so the full line is the same as the high point in the motor. If you put it in the inlet side, that may be hard to achieve. Also having it the same height allows space for an air cushion in the system when the coolant heats up.