Radiator vomiting. - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 3 Old 10-08-2014, 04:02 PM Thread Starter
1st Gear
Join Date: May 2010
Location: Oklahoma City, OK
Posts: 17
Radiator vomiting.

My '07 has 18900 miles on her, and has performed flawlessly since I bought it in 2012.

Last week I noticed an anti freeze smell while riding to and from work Friday. It never overheated, and I couldn't tell where it was leaking from at that point.

Saturday I looked at her cold, and sure enough, there was dry anti freeze residue drops all over the front of the engine. I took off the radiator cap and it was full. So I started the bike and just let it run with the cap off, and as it ran, the coolant level rose and started to run out the top.

Coolant systems have always tripped me up, but I'm guessing thermostat, water pump or radiator cap in that order. Does anyone have any other ideas?

By the way the coolant was green and clear.


Retired USN 1985 - 2005

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2007 ST1300
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post #2 of 3 Old 10-08-2014, 04:27 PM
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Join Date: Mar 2007
Location: Fort Sask , Alberta, Canada
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Is the hose from the rad to the overflow tank pinched or plugged?

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

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post #3 of 3 Old 10-09-2014, 06:54 PM
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Join Date: Oct 2013
Location: Chilliwack, BC, Canada
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Not likely thermostat as don't recall hearing of a KLR stat failing. +1 on the overflow hose to the tank being a problem. Check hose clamps first as they can back off. Assuming you have the normal screw adjusted gear clamps? If so, back each clamp screw off a bit, then squirt some penetrating oil onto the screw and snug up. The screws often stick (not really seized) so it's hard to start moving. No need to go crazy tightening.

Most likely the overflow hose is cracked/holed and losing coolant drops as the engine heats up. If that's the case, on cooling air will enter the hose and into the rad. The air can collect in the thermostat housing area and displace coolant, especially with the rad cap off. Normal for a full cooling system to lose coolant when the cap is off and engine warming up.

Once in a while a coolant hose leaks but not common. I'd check that overflow hose, and the bottle to make sure it's not cracked or punctured. If in doubt, pull the hose off the tank and put the tank end into a clear bottle, then re-install the rad cap and run the engine to see if you still lose coolant.

I'm also assuming you don't have a by-pass system such as the Thermo-Bob installed?
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