Bike won't hold coolant after clutch replacement - 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 5 Old 05-25-2019, 04:24 PM Thread Starter
Join Date: May 2019
Location: Southwest Colorado
Posts: 2
Exclamation Bike won't hold coolant after clutch replacement

This is my first post on the forum so excuse my ignorance.

I just replaced my clutch, and impeller and now when I try to replace my coolant it all drains out of the weep hole. The bike will run for about five minutes before the thermostat runs into the red. The radiator fan works but doesn't turn on when the bike starts to heat up. Everything involving the radiator is stock besides a thermobob mod. I'm guessing it's an easy fix since everything was working correctly before the clutch went out I'm just an inexperienced mechanic.
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post #2 of 5 Old 05-25-2019, 07:29 PM
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Join Date: Nov 2015
Location: Antioch Florida
Posts: 541
Back in October, I got into a situation where fluid was leaking out the weep hole and I had to take the cover off to replace the water pump seal in the cover. I do a lot of my own work and that was a bad experience. At the same time I replaced the two seals in the water pump, one of which was the mechanical seal that opens the weep hole under pressure. Long story shortened...after ruining one seal and finding that the second seal did not fix the problem, I conceded and took to my dealer (TampaBay Power Sports), who promptly determined that the water pump shaft was bent. The bike was a 2016 that I bought brand new and I need to accept that I probably bent it fighting the seal and getting the case back on. So on that note, don't take any of my advice. However, there may be some insight in the thread where we discussed this disaster, including the warning about taking the cover off and, of course, the true mechanics in the group will have some thoughts for you.
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post #3 of 5 Old 05-26-2019, 04:29 AM
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Join Date: Jan 2011
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For clarification: By, "replacing" the clutch, do you mean replacing fiber clutch plates only, or more extensive maintenance?

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post #4 of 5 Old 05-30-2019, 04:51 PM Thread Starter
Join Date: May 2019
Location: Southwest Colorado
Posts: 2
I replaced the fiber and metal plates as well as the springs. When I replaced the clutch I also replaced the clutch cover gasket and water pump gasket.
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post #5 of 5 Old 05-31-2019, 05:42 PM
Join Date: Nov 2009
Location: Lander, Wyoming
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I recon that I will ask if the coolant is draining from the Threaded drain plug hole in the bottom of the water pump cover or from the weep hole between the water & oil seals in the clutch cover?

If actually Draining from the weep hole, one must have left part of the water seal OUT of the assembly.

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Still riding my 1987 KL650-A1. 85,000+ miles & counting
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coolant, klr 650, leaking, radiator

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