Well I went last week with my friend when he bought his '03 P650. He and I have been riding together three times now (me on the Lakota). Every time he rides, it begins to spit coolant from the overflow tube coming from the overflow container. I traced the tube from that container and it ends over the front exhaust pipe on the left side of the quad behind the splash guard. The temperature here has been in the 90's and he's following the 1/2 throttle or less routine until his 10 hrs are up. He and I have already witnessed the new coating burning off the engine during the first warmup and ride. Anyone else had any problems like this during break-in? I realize the engine may run hotter during break-in, but I'm a little worried for him with it losing coolant. It's gone from showing just under full on the indicator to just above the low level. He's gonna refill today after work, but what's gonna stop it from continuing to blow out in the future? Any ideas or suggestions?

 

Hey there. My 650 has leaked anti freeze to and it leeks on to the exhaust pipe to. I took all my plastic off and tighted up some of the hose clamps and now it does nopt to it. Mine did not leak that much thow. In 6 monthes it leaked from the full to the low. LAter all. hope this helps.

 

I'd take it back and have the dealer fix it on his nickel....

 

That coolant fill neck has been the culprit causing coolant loss out the bottle on many quads.

-It is plastic and warps, or something. Mine looked like it was eaten by chemicals. I am hopng for someone around here that can fabricate us an aluminum replacement. I replaced it and it is fine for now.

-The coolant strainer (near card float bowls) is also crappy. Mine melted.

-The radiator fan bracket sometimes looses a spot weld, and proceeds to mess up the radiator.

These are three things to maybe watch out for.

 

Nyroc--Having not "seen" what you are talking about, would it make sense to wrap these items with a heat-reflective fiberglass tape?

Chucky

 

You can't really do that to the fill neck, not room to do it. I am sorry to say that I really don't know for sure why these coolant necks suck. I just know that mine and few other people's fill necks have leaked.

The strainer is ok as long as it does not get clogged, which mine did when a coolant additive formed globs and stopped the flow. It can probably be replaced with a brass fitting (I used one for a while). I am not entirely convinced of the need for the strainer.

 

My friend and I both bought 650's at the same time. First day we rode for about 30 minutes and stopped by a stream. I looked over at his machine and he had coolant burping out. If we'd sit for 10 minutes he'd be ok. We looked at all of the items I had seen on the forum prior to buying these mean machines. It turned out that the dealer had simply neglected to hook up his cooling fan during prep. The dealer confirmed that this is part of the process they are to follow but sometimes miss. Is his fan turning on? sounds simple but easy to overlook. Good Luck!

 

PrairieSlider - His cooling fan is connected and cycles on and off during riding and even after the quad is switched off and sitting.

Nyroc - was your coolant leaking from around the cap on your overflow bottle, or was it flowing from the tube attached to the bottle?

When the coolant leaks, it drips onto the front header pipe and also wets the left front vertical frame tube. We are about to just remove the front plastic and see if it's leaking anywhere else as well.

 

I had a bad radiatore that kawi replaced under warranty. The cross flow tubs where not soldered to the tubs properly. Just something to look at.

 

I did not look to see where it went when it was leaking, I just replaced the neck. I lost my coolant bottle cap on the trail at the same time.

My fill neck had rough, distorted plastic at the pressure retaining surface seal (not the outer seal), so it leaked coolant into the bottle. I just noticed the bottle filling up, I did not see where it went.