I am dripping antifreeze from both sides of the radiator where the plastic sides are attched to the metal core has any one seen this on their 650. Could it be leaking some where else and running down the sides making it look like the sides are not bonded well to the core? Any sugestions. Thax

 

check your filler cap assembly. It is where the radiator cap is. A few of us mudders have had problems with it corroding and leaking.

 

I will look at it closer tonight I looked at it yesterday but it felt tight so I didn't take it off to check it. I will though and if not I will take of the plastic and check it better to make sure its what I think it is before I call and take it to the dealer.

 

Just like northark said, my fill neck was making the radiator look like it was leaking. I don't think there is anything bad about our radiators (I think they are all metal too, can't remember seeing plastic).

My 650's cooling system is officially holding water now! Yeehaa! I will not replace the neck again. I found a way to make that part myself if it ever leaks again. It will suck to do it, but I am not going to keep pouring money down that crappy little fill neck.

MonteSS, one guy I met had a problem with his radiator fan bracket being loose and fatiguing his radiator and makin it leak. The bottom finger that goes from the radiator to the fan mount ring was inproperly spot welded. I fixed mine when I took the radiator out. you might wanna look at yours if you take anything out. I just mig welded mine. Better than new.

 

Okay I will check that also it looks like it is on both sides dripping off I hpe it is something simple if not Thank gad it is still under warrenty! I just hate to have them touch it.

 

nyroc, enlighten me!! i dont wanna pay the bastards 80 bucks for the filler neck.

monteSS, look at the filler cap assembly and see if it looks corroded or melted inside.

 

2 ways so far:

-buy a fill neck from some place like perma cool and have it welded (I can't weld aluminum) to tube, plate, pipe to make up an aluminum replacement for this plastic crap. Places sell these fill necks for racers who custom build radiators. I have found a couple, but I think they are for the standard cap, not the small one.

or

-get an aluminum block and mill the bore and 2 steps for the radiator cap seals. Drill and tap for one large and one small pipe fitting for the hoses. Drill holes to mount in same location to same flange as plastic neck was. As for the cap, I would drill the top rivet and use just the guts of the cap, sandwiched between a plate and this machined block. I know this sounds like it would be hard to fill, but I would fill the system using a winshield washer pump (or the H.L. radiator shower pump) connected to the carb coolant strainer hoses. One additional fitting and hose needs to be drilled near the top of this machined block to let the air out when filling, but that is no big deal.

You would never need to get the plastic off to fill the system. This is the best idea I could come up with my very limited machining opportunities. I only have access to a drill press. I hope I would not need more tools than a drill press.

I might be able to draw this in a shaded 3d image if it is cloudy to you.

I am still looking for ideas.

 

Well bad news I took every ones sugestions and looked at every thing.I pulled the entire front plastic and racks and splash gaurds off. I even tightened the hose clamps that where kind of loose to me kno leaks. So I started it up and left here run till the fan was coming on and left it run for a while the cross flow tubs to the side tanks did not seal right and it is leaking from the radiator from the 4 or 5 one down on the right side[img]i/expressions/face-icon-small-sad.gif[/img] I am going to call the dealer and have them order me a new one thank God it is still under the 6 month unlimited warranty[img]i/expressions/face-icon-small-smile.gif[/img] I will keep you posted on what happens.

 

Called the dealer it goes in Saturday for about 2 weeks they said and the radiator runs about 500 dollars OUCH. Just letting ya know.

 

Nyroc...whats your last name ... MacGyver?