Gen 3: 2008-2010 Cooling system issues solved - Kawasaki
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post #1 of 2 Old 03-22-2019, 10:58 PM Thread Starter
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Cooling system issues solved

Picked up a neat 2008 a few weeks ago and decided to give it a full service...

When bleeding the cooling system, the bike got a bit hot (104 degC) so I switched it off.
It then proceeded to dump half the coolant out the overflow pipe and the reservoir was bubbling furiously.
Within 30 seconds it had sucked the reservoir dry.
Thought it might have been some trapped air or a thermostat issue so I topped it up and have been keeping an eye on it.

Yesterday's commute home was fairly warm and it spat the coolant out again.
Been diagnosing it this morning and there was no pressure in the hoses.
When the lower hose is squeezed, the reservoir level rises and falls.
Changed the radiator cap to no avail.

2008 radiator has 2 x 10mm pipes at the radiator cap - one under cap seal level (going to the thermostat housing) and one above cap seal level (going to the reservoir).
Turns out the person who last owned/worked on the bike had fitted the hoses arse about.
Swapped them back and now it runs like a champ.

Easy mistake if you don't know what you're doing - hope this helps anyone else who runs into similar issues.

Last edited by unsane; 03-22-2019 at 11:19 PM.
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post #2 of 2 Old 03-22-2019, 11:19 PM Thread Starter
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