Hole in rad? - Kawasaki Vulcan Forum : Vulcan Forums
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post #1 of 7 (permalink) Old 05-21-2017, 01:35 PM Thread Starter
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Hole in rad?

Noticed a leak seems to be coming from the bottom left hand corner. Not a lot but enough to watch it drip on the ground. Is there something I can put in the rad to plug the hole?. I actually dont see the hole its just wet around that area.

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post #2 of 7 (permalink) Old 05-21-2017, 01:37 PM Thread Starter
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Also do the small rubber gromets come off without taking the whole rad off?

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post #3 of 7 (permalink) Old 06-02-2017, 09:45 PM
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Jau Jay

I had the same thing just happen to mine last week. Sadly I caused it while bolting on highway bars and prying on the bars to make them fit accidentally hit the rad and made it leak in the same place. Looked around for replacement and the price fixing $500.88 seems to be the norm.

So why I am telling you this is because was able to repair mine using Low Temperature Aluminum Welding Rods from HF. I used a regular propane torch and was able to weld the little tiny hole on the post holder on the bottom Same as yours. I have had those rods for over a year looking for a project to use them on (to be honest) I was skeptical if they would work....but 5 try's later it was sealed. I put the radiator in a water tub and pressure tested it all good. This also provided me the opportunity to change the antifreeze.

All good now, $16 dollar fix. I hope it helps.

BTW you do need to pull the rad, it's not bad at all, had to do it multiple times. Once you undo the screws you need to unclamp the both hose clamps top and bottom that will allow you to gently lift the rad off the rubber holders and remove it for service.
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  • 03' Vulcan 1600 Classic
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  • Chrome Engine Guard
  • Classic Windshield
  • Vance & Hines Big Shots Staggered
  • Dynojet Power Commander III
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  • Archoil AR9100 Oil Additive
  • Archoil AR6200 Fuel Modification

*Not a motorcycle mechanic in real life but I did stay at a Holiday Inn Express last night*

Last edited by Filichezst8k; 06-02-2017 at 09:51 PM. Reason: add infomation
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post #4 of 7 (permalink) Old 06-02-2017, 09:51 PM Thread Starter
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Quote:
Originally Posted by Filichezst8k View Post
Jau Jay

I had the same thing just happen to mine last week. Sadly I caused it while bolting on highway bars and prying on the bars to make them fit accidentally hit the rad and made it leak in the same place. Looked around for replacement and the price fixing $500.88 seems to be the norm.

So why I am telling you this is because was able to repair mine using Low Temperature Aluminum Welding Rods from HF. I used a regular propane torch and was able to weld the little tiny hole on the post holder on the bottom Same as yours. I have had those rods for over a year looking for a project to use them on (to be honest) I was skeptical if they would work....but 5 try's later it was sealed. I put the radiator in a water tub and pressure tested it all good. This also provided me the opportunity to change the antifreeze.

All good now, $16 dollar fix. I hope it helps.
Actually I fixed it using JB weld marine epoxy just sucked having to take everything apart to get at it. But on the brighter side I got to do a rad flush and so far no leaks at all...best $10 I ever spent.

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post #5 of 7 (permalink) Old 06-02-2017, 09:56 PM
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Funny thing I went that route also, used JB marine weld left it over night But it did not work for me next morning rand the bike and saw dripping, luckily it came off and i was able to wire bush the area and weld it.

I am glad it worked for you save you a bunch of work.

  • 03' Vulcan 1600 Classic
  • Fire and Steel Tachometer
  • Chrome Engine Guard
  • Classic Windshield
  • Vance & Hines Big Shots Staggered
  • Dynojet Power Commander III
  • Mobil 1 Racing 4T 10W-40
  • WIX 51358 Oil Filter
  • Archoil AR9100 Oil Additive
  • Archoil AR6200 Fuel Modification

*Not a motorcycle mechanic in real life but I did stay at a Holiday Inn Express last night*
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post #6 of 7 (permalink) Old 06-03-2017, 08:43 PM
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Glad you got it fixed. If it doesn't hold, do not use any kind of stop leak in any vehicle that you care about. My dad had a radiator shop. We chunked a lot of radiators that would permanently plugged with stop leak. We also chunked a few water pumps because of it.

If you try to do the aluminum welding (actually brazing since you are not melting the base metal), be sure to clean it really well. No oils (and don't clean with any petroleum solvents, either; alcohol is best), no aluminum oxide left on the surface. That is the biggest mistake folks make when using aluminum brazing rods. Use a brass brush, not a steel brush if you are brushing. Flux also helps (or get flux coated rods). We repaired radiators with these rods and they worked great, but only if the surface was absolutely clean.
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post #7 of 7 (permalink) Old 06-04-2017, 10:49 AM
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I agree with that 101%.....CLEAN is CLEAN and anything short of it will yield piss-poor results when brazing or soldering. Use plenty of flux, too!
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