So far, northark, I have found aluminum fill necks that fabricators use on race car radiators. We could easily get a fill neck welded to some aluminum tubing or a block or something and drill and tap it for whatever hose fittings.

the problem is that these are all for a standard radiator cap. If we found one for a smaller cap, might work out.

I also think I could modify a cap to fit in a block of aluminum (sandwitched under a plate and never to be removed), and bolt it to the thermostat housing (with two hose fittings one big one small). This would take a machinist to do some stuff for me. I have machine shop experience. Maybe my bro could smuggle me into the college and make it. This idea may require a petcock and a some kind of widshield washer pump to fill the radiator if it is too hard to get the plastic off, to fill it. I used to be a drafter, I could draw this block thingy up electronically and see how much it would cost to make it.

Do you think there is any way to convert the cooling system to use a pressure bottle like a some cars, and my truck? If you did this, and put the bottle under the seat somewhere, you would never have to take the body plastic off to put coolant in. I won't do this, since I plan to leave access to the radiator cap where it is.

One more fill neck problem and I am done with it. I will make a modification. I will not buy another fill neck.

 

I HAD THIS PROBLEM YESTERDAY. MY OVERHEAT LITE CAME ON AND I STOPPED AND SEE ANTIFREEZE LEAKING BUT COULD NOT FIGURE OUT WHERE. I WAS THE ONLY ONE TO OVER HEAT ON THE RIDE EXCEPT A 660 GRIZZ DID WHEN WE STOPPED FOR A WHILE. WE WENT TROUGH A LOT OF MUD AND RADIATOR WAS PLUGGED BUT I WAS NOT IMPRESSED THAT MINE WAS THE ONLY ONE TO OVERHEAT (3 TIMES ) IT DIDN'T LEAK TO MUCH THE COOLANT BOTTLE WAS FULL. DO YOU GUYS THINK THE MUD IN RAD. WAS THE CAUSE OF THIS OR SOMETHING ELSE ALSO MY FAN RAN ALL THE TIME ABOUT 10 MIN AFTER SHUT OFF.

 

Bluerhino, if your fan runs alot it is probably too much mud in the radiator. Not enough water also does this.

Lets us know where you are leaking from, I really think we can fix this (wish kawasaki would fix it). Your quad would not have worse cooling in the mud than anyone elses if it was not leaking.

 

NYROC > RADIATOR IS FULL SO IT HAS TO BE THE MUD. IT ONLY LEAKED A LITTLE BIT FROM THE LOCATION I THINK ITS THE FILLER NECK THATS THE ONLY THING IT COULD BE WHEN I GET A CHANCE I WILL LOOK IN TO IT MORE.

 

hey this rad problem is on heard of. is this heat induced or chemicals. right of the bat i drilled 12 or so 3/8 holes in air box cover the removeable plastic you cant believe the heat that escapes there