Coolant leak - 2003 klr - 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 21 Old 11-28-2017, 05:43 PM Thread Starter
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Coolant leak - 2003 klr

Hi everybody, started to smell coolant a few weeks ago. I switched out the rad and pump hoses, assuming one had a small leak. I refilled coolant levels, and now (not before) have coolant leaking from where the exhaust pipe meets the exhaust manifold. I cant really see anove the area to see if theres an upper rad hose that leaks.

Ive checked the cap, and overflow jug. The levels are good, but im guessing slightly down. The odd thing is the leak starts on startuo (takes about 20 secs to start), the stops. After i ride for a bit theres no leak. Stumped!
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post #2 of 21 Old 11-28-2017, 05:49 PM Thread Starter
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Sorry, tried to edit my last post, but not able to. Tried to add a video, but cant. Thats why theres a pic there
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post #3 of 21 Old 11-28-2017, 05:56 PM
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Type in the URL for your video, but bodge it up a bit by putting spaces in the http and between the . and com.

I'll fix it for you so we can see it.

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post #4 of 21 Old 11-28-2017, 07:40 PM
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The Upper radiator hose is in that pic.

Is there maybe some coolant weeping from the thermostat housing 'o'-ring and drooling forward on the cooling fin?
The pic looks to have some "shine" in that area.

Could be just the excuse needed to add a Thermo Bob 2, Re-circulating thermostat assembly. It comes with a new 'o'-ring for that area.

OH, And welcome to the forum.
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post #5 of 21 Old 11-28-2017, 08:16 PM Thread Starter
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Thanks guys, for chiming in on this. Lets see if this link works https://www.dropbox.com/s/g6rgjtl15c...20650.MOV?dl=0


Last edited by Tom Schmitz; 11-28-2017 at 08:49 PM.
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post #6 of 21 Old 11-28-2017, 08:27 PM Thread Starter
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I did install an exhaust gasket a few months ago. Metal gasket, which sits inside the manifold. I did cinch the bolts down today, making sure they hadnt rattled loose. But it still leaks , just for about 2 to 3 mins after startup.

Ill check the upper rad hose you mention tomorrow, it would make sense, that its sonething dripping down, but its a hard to see area. I did the oil about 4 wks ago, not milky or fluid filled
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post #7 of 21 Old 11-29-2017, 11:00 AM
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I'm pretty certain I can see the 1st drip at about 10second mark come off of the lowest cooling fin, just slightly above and behind the exhaust manifold & header. And I can still see the 'shine' below the thermostat housing, above that lowest fin.

With a dry & cold engine, spray several coats of foot powder (dries white or gray) on the suspect areas, allow to thoroughly dry.
Start the engine, the dry powder will dampen & stain very quickly, identifying the source of the leak.

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post #8 of 21 Old 11-29-2017, 04:51 PM Thread Starter
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Thanks pdwestman. I checked the area this morning, and see/saw exactly what u described. I tightened the 3 bolts in the pic, and the rad hose, too. Ill report back on if it worked, i believe it will - they were all able to be tightened a bit.

Ill let you know. Appreciated!
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post #9 of 21 Old 11-29-2017, 05:39 PM Thread Starter
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Still leaks. Starts 15 seconds after start and last until i shut the choke off.

Is there a gasket that surrounds that 3 bolt mount in the pic?
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post #10 of 21 Old 11-29-2017, 07:16 PM
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Be extremely careful about tightening small bolts trying to stop a leak. Very easy to twist OFF.

There is a square section rubber sealing flange on the thermostat. The rubber sealing flange/ring is NOT sold separately of the thermostat! Thermostat part #49054-1053.

There is probably corrosion formed in between the sealing ring and the thermostat cap/elbow. If one drains the coolant, removes the elbow/cap and cleans the corrosion off of the aluminum and the rubber sealing ring, it may possibly re-seal.

By your 'morning' comment, you must be across one ocean or the other from USA.

One might be able to use 2 separate "o"-rings on either side of the brass thermostat flange to create seal, if cleaning the square section sealing flange does not work.
Or silicone RTV gasket sealant, on square section sealing flange.

pdwestman
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