monteSS - how did you notice that the internals of your radiator where assembled wrong? Did you notice it from the radiator cap opening or was it obvious from the outside? Was your quad overheating or spitting/burping coolant out the overflow?

nyroc - this guy's bottle is slowly emptying out. I get your problem of the radiator cap not sealing properly and filling the overflow bottle. I'm thinking maybe he has a loose hose fitting like Scrode mentioned he had on his. That would explain the overflow bottle level dropping. Any other ideas?

 

I noticed coolant leaking out a few times and passed it off for the over flow. Finally I put card board under the machine and saw ecxatly where it was coming from before I moved it. I took all the plastic off the front and the side splach gards and turned it on and let it run and heat up until I saw coolant flowing and looked for the "wet spot" and it was the 4 and 5 row down into the right tub. Best thing I found to do was just take the plastic off, it takes me about 10 min I have had it off so much and start it up and let it run till you see the "wet spot" takes most of the guess work out of were could it be comming from.

 

Ok guys... Took the plastic off after it began leaking once it was hot and the leak was coming from a loose radiator hose clamp. Tightened the clamp -- leak is gone. Case closed! Let's ride!

 

Whew[img]i/expressions/face-icon-small-smile.gif[/img] Sweating that one weren't you. I was hoping for the same thing when I found the radiator leak. I was hoping not to have to take it into the dealer and be without it for 3 weeks.