Mysterious Coolant Leak.... - 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 8 Old 04-03-2020, 02:19 PM Thread Starter
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Mysterious Coolant Leak....

Hey fellas. just busted out the 03 from her winter sleep and so far so good. I wanted to do a good old fashioned coolant flush, and that's where the weirdness began. I drained the old coolant out, the ran just plain water through the system. Then I drained that out and added Blue Devil radiator flush and some more water to top it off. Ran the engine to purge any air, then topped it off with more water. I Then took her for stroll around the block just to run that stuff through the system and then put the bike away for the night.

I was in my garage the other day doing something else, and I heard a periodic venting sound coming from the bike. I notice a small drip coming from from the hose connection that enters the bottom of the cyclinder. the Leak would increase whenever the coolant system would go through one of those periodic venting cycles. So I went ahead popped the radiant cap off and there was a rush of air out of the top of the radiator as the coolant system decompressed and splashed coolant everywhere. The bike wasn't hot at all, not really sure what the heck was going on there. I topped the radiator off and then checked it the next day and it did the same exact thing.... not sure what tis going on here. It appear my radiator is leaking now too and when it wasn't before. Not sure if it cracked under pressure or something.

It appears the coolant system is not decompressing properly after the bike is ridden. Im not so concerned about the leaking radiator but more about my entire coolant system itself.
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post #2 of 8 Old 04-03-2020, 02:44 PM
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Did you leave the 'radiator flush' in over night? Any kind of 'Flush' should be drained & rinsed out on same day.

I'll suggest that you need to remove the coolant overflow hose from the Bottom of the coolant Reservoir & drill the passage way open.
Header pipe overheating (from too much motionless idling) & the tension of the hose & spring clip have been know to Totally Collapse that plastic nipple.
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post #3 of 8 Old 04-03-2020, 03:14 PM
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It's a guess but there's probably some small amount of some kind of an acid in there that's cutting away at the crud. And that stuff will release gasses as it works. It pressurized the system.
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post #4 of 8 Old 04-03-2020, 04:07 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
Did you leave the 'radiator flush' in over night? Any kind of 'Flush' should be drained & rinsed out on same day.

I'll suggest that you need to remove the coolant overflow hose from the Bottom of the coolant Reservoir & drill the passage way open.
Header pipe overheating (from too much motionless idling) & the tension of the hose & spring clip have been know to Totally Collapse that plastic nipple.
Ive had that wrapped up with heat reflective tape so it hasn't melted away and is still in good shape. im thinking I didn't have the radiator cap on all the way so maybe the overflow hose was blocked.
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post #5 of 8 Old 04-03-2020, 08:03 PM
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MTKKLR, Remove the overflow hose from the radiator neck and blow in it. One should readily hear the bubbles in the coolant reservoir.
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post #6 of 8 Old 04-03-2020, 09:05 PM Thread Starter
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MTKKLR, Remove the overflow hose from the radiator neck and blow in it. One should readily hear the bubbles in the coolant reservoir.
I will certainly try that thank you very much.
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post #7 of 8 Old 04-05-2020, 08:38 AM Thread Starter
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Originally Posted by pdwestman View Post
MTKKLR, Remove the overflow hose from the radiator neck and blow in it. One should readily hear the bubbles in the coolant reservoir.
Hey pdwestman, so I did what you said and could hear bubbles in the reservoir no problem. As for now I have a new radiator on the way because the old one had a bad leak. Once I get it all put back together ill try it again and go from there. Thanks for the help.
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post #8 of 8 Old 04-06-2020, 11:37 PM
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I just discovered my coolant overflow tank had the bottom nipple melted as you described. Sealed completely. Then my radiator blew. Then I have bubbles in my coolant. Could the simple blockage cause all this damage?
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