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During my frenzied list of mods for winter, I Had the lower fairing off to install my EVO 2 exhaust and found A coolant leak around the water pump. Has anyone else had this problem? If so is it a reoccuring concern?
 

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Been there, done that. Took it back to the Kawi dealer and had the entire pump replaced under warranty. They said that it was a sealed unit and there was no gasket to replace. I also got a call yesterday after compaining about hairline cracks in the mid fairing around a allen head bolt. Their replacing that under warranty too. My dealer, Steve Baker kicks ass!
Take it it if your still under warranty and have them fix it.
 

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I had a coolant leak there which happened because I accidentally pinched the hose from the radiator cap to the coolant bottle when installing the lower fairing after an oil change.

After that happened, I flushed the system out completely and replaced the green coolant with Volkswagen G12 coolant / distilled water. The VW G12 coolant is phosphate-free and is the best coolant specification that I know of, as long as you don't mix it with anything else. No issues since.

For some reason, it takes a *long* time for the air bubbles to work their way out of the cooling system on these engines ...
 

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yes that happened to me i took it in then got my bike in a few days. the water pump seal was out.
 

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GoFaster said:
For some reason, it takes a *long* time for the air bubbles to work their way out of the cooling system on these engines ...
You noticed that too ehh?
 

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Unfortunately there does seem to be an issue with the water pumps in some of the ZX-10R's, as I too started to notice coolant dripping from under my bike upon coming home from a ride, about a month ago (bike has 3K miles on it). After checking the tightness of all fittings, I finally determined the fluid was coming out of the inspection hole at the back/bottom of the pump, due to coolant leaking past an inner seal on the rear of the pump housing.

My dealer allowed me to do the work, in pulling the pump off myself, and then getting a replacement provided under warranty, which I then installed. While I still had the old pump, in opeing it up, I found a lot of very fine aluminum metal shavings that had settled in the rubber O-Ring that borders the perimeter of the outer cover plate of the pump. Obviously signs of something rubbing/wearing away, within the pump.

My suspicion is that the material of the pump housing must have been gradually worn away somewhere around the shaft/seal area, until the clearance finally got large enough for coolant to leak past.

What's odd is that the bike would sometimes drip a solid stream of coolant at one moment, when started up or returning from a ride, and then allow me to ride for several hundred miles that same day, with numerous stop/sit for a bit/and start again, without showing any more leakage that day. Very odd!

If wear on the metal of the pump housing and/or shaft was the cause of the fine metal shavings, and leaking pump, I hope that Kawasaki has had time over the last 10 months to realize the shortcoming of the pumps (which they buy from an outside vendor), and have some modifications done to the construction of the one that I now was given as a replaement. Time will tell, I guess.

Hope this personal experience on the pump leakage problem might be of help.

Gary J
 

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that sucks my dealer handled everything.
 

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stunnerific_harry said:
that sucks my dealer handled everything.
Actually Harry, doing the work myself, was totally my choice ... and actually something they allowed me to do only because I have a very close relationship with them from lots of years.

Being a mechanical guy, and roadracer, I personally wanted to know more about what was causing the leak, on such a new bike. I felt I'd be better prepared to look for future issues, if I knew more about the details of the failure.

Also, I didn't really want anyone else working on my "new baby" at this point, unless absolutely necessary. :smile:

Gary J
 

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thats koo then
 

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The part number didn't change from 2004 to 2005, so I better keep an eye on mine too.
 
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