if anyone has had problems with their filler cap assembly or any coolant problems post here. I believe Kawasaki needs to replace the faulty filler cap assembly with a aluminum one.

 

Hmm, maybe I have this problem. I notice on my first ride (only ride so far) that I had coolant leaking out of the refill cap. After getting home, I noticed that the cap seems kinda stripped. It only tightens up so far then seems to "pop" loose again if I keep turning. I have to stop tighening it before it does that "pop". And then it does not feel tight enough.

 

look for corrosion in the cap assembly

 

-My Filler cap looked like the plastic had been burnt, corroded or bubbled. This caused it to leak coolant into the bottle.

-My coolant strainer popped and let the coolant out (no overheat light was on). I still don't know why it burst. It looks melted from heat, but the motor wasn't very hot.

-My water pump seal started leaking. Absolutely no clue why it leaked.

I have fixed these things myself and the parts add up to around $110.

 

Mickey Dunlap put a High Pressure cap on mine when he built my motor.

 

high pressure cap wont work. what we need is a aluminum filler cap assembly. as of now mine isnt overflowing because i plugged the overflow with j-b weld. now i just need a temp guage to know when and if it gets hot.

Nyroc, if your gaskets still leak, get some blue rtv silicone(gasket maker) and use that instead of gaskets. It will seal.

 

northarkie650MUDD, are you speaking of the cap on the radiatopr itself? Or the coolant bottle down near your left foot? I have not checked the rad cap, but my problem is with the coolant bottle.

 

whats wrong with your coolant bottle? my problem is what the cap GOES on to, the filler cap assembly.

 

Just a recap for those not following the subject, the radiator cap is under that plastic access cover in front of the ahndlebars. It is made of composite plastic. The raised ring of plastic that the radiator cap seals against to create 14psi, is leaking coolant, which therfore goes down a tube into the bottle.

Somehow we need to make a fix for this thing, since it distorts or melts or erodes or something.

If we were to revamp this thing and create a separate the fill cap and pressure valve and check valve (radiator cap has these 3 distinct functions), we would be able to get around this leaky plastic thingy.

 

yes, we definetly do. Mine is leaking coolant somewhere but i have no idea where. monday im going to order a temp guage from HL to make sure i dont overheat it july4.