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Old 12-05-2005, 06:55 AM   #1
Pointman0853 OP
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640 Adventure disappearing coolant problem...SOLVED!

I finally pulled all the hoses and radiators off my 640 Adventure to try and find where the coolant was going to.

My local dealer pressure tested both radiators and found the right one leaking up around the filler neck. Further inspection found the overflow nipple to be the culprit. As the radiator cap would vent coolant to the overflow, it would leak out here and evaporate leaving no clues...

Problem is, the whole thing is made of aluminum, and the nipple is some POS pressed in plastic thing! WTF was KTM thinking on this???

So now I either need to find a way to have a bit of short aluminum pipe welded on to this impossibly small area, or buy a new radiator... Can aluminum be soldered or braised??? I think not.

At least It looks like I won't need to be pulling the head off...

Pointman
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Old 12-05-2005, 07:20 AM   #2
LKN4DRT
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Could you use epoxy or JB weld?
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Old 12-05-2005, 08:07 AM   #3
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Take it to a good radiator shop, you may be suprised.
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Old 12-05-2005, 10:46 AM   #4
Pointman0853 OP
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Radiator suprise!!!

SUPRISE! The radiator shop says they cannot fix it by welding....

I have some nasty two part epoxy given to me by a friend that is used on cruise missles or some such thing, and I'll try this.

Ima' bit concerned about long term hot/cold cycles effect on this, but my only other option is to get 'bent over' at the dealership for a new un'

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Old 12-05-2005, 11:25 AM   #5
craigincali
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Intersting, doesnt sound like it would be that hard to fix.
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Old 12-05-2005, 11:39 AM   #6
clintnz
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I cracked my rad a while back & the rad shop fixed it with some epoxy stuff which is still holding 10000km later.

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Old 12-05-2005, 11:46 AM   #7
Jim Bud
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The trick to a good epoxy weld is surface preparation...

Quote:
Originally Posted by Pointman0853
SUPRISE! The radiator shop says they cannot fix it by welding....

I have some nasty two part epoxy given to me by a friend that is used on cruise missles or some such thing, and I'll try this.

Ima' bit concerned about long term hot/cold cycles effect on this, but my only other option is to get 'bent over' at the dealership for a new un'

Pointy
It must be very clean...and free from all grease and wax....and moisture...

and roughing upthe surface with emery paper will only make it stronger

If you do the surface prep well. it will be very strong and last a long time....
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Old 12-05-2005, 12:08 PM   #8
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Quote:
Originally Posted by LKN4DRT
Could you use epoxy or JB weld?
Yep, JB weld is about the only thing that will work on a alluminum radiator. People have been fixing motocross radiators with it for years. I had patched a leak on my VFR800 radiator and it was still holding just fine 80,000 miles later when I sold it.
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Old 12-05-2005, 09:35 PM   #9
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If you ever have coolant loss without any leaks, pull the gas tank and remove the breather tube that goes to the tappet cover. If its full of white milky snotty goo, replace your water pump seal. Don't remove the LC4 head looking for a leaky head gasket.
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Old 12-06-2005, 06:42 AM   #10
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Before you buy a new one (if the epoxy doesn't work) give Mylers a call. They specialize in motorcycle radiators and might be able to save it. I just had a severely bent rad. from my 450 EXC repaired by them and cannot believe how straight it is now. Cost me $70.00 including shipping, new is $199. Infact, you may want to call them BEFORE you gunk it up with epoxy. Good luck.

If the link doesn't work their number is 800-367-7699.
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Old 12-06-2005, 08:21 AM   #11
Hornet
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Myers Rocks

I second the Myers suggestion. When I got my DR650, the radiator was 'customized' by the previous owner in a drunken rage with a crowbar. They patched a small leak and straightened it out beautifully. The results were remarkable and the damage is not even noticable.

$80 including shipping and the turnaround was a week and a half (shipping from New Jersey to Utah and back included!).
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Old 08-15-2006, 05:12 PM   #12
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mylers

I will third that motion...

I got my radiators back so fast is was silly... It only cost me $75 to fix the radiator on my old rmx 250. That radiator was crushed, and bent. It worked perfectly when I got it back..

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Old 08-15-2006, 09:18 PM   #13
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Your radiator can be TIG welded.
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Old 08-15-2006, 10:27 PM   #14
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Quote:
Originally Posted by Hornet
I second the Myers suggestion. When I got my DR650, the radiator was 'customized' by the previous owner in a drunken rage with a crowbar. They patched a small leak and straightened it out beautifully. The results were remarkable and the damage is not even noticable.

$80 including shipping and the turnaround was a week and a half (shipping from New Jersey to Utah and back included!).

DR650- radiator
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Old 08-16-2006, 11:50 AM   #15
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Quote:
Originally Posted by GODSPEED
DR650- radiator

Oil cooler?
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