VULCAN COOLANT LEAK KNOWLEDGE BASE

[trikebubble]

This thread was created to consolidate and share information on this seemingly common issue. Please feel free to add any pertinant information, or pictures and schematics that may help other Vulcan riders find and repair these coolant leaks.

It seems apparant that many Vulcan cruisers have issues with small coolant leaks. Both of my previous Vulcans (Mean Streak 1600 and vulcan 2000) had this problem.

In my case, and as it seems in the majority of other cases noted here, the coolant leak is coming from loose coolant hose clamps. Again, from my experiance and the information gathered from others, the loose hose clamps are the smaller ones (around 3/4" diameter or slighlty larger) and are attached to coolant hoses that lead to or from the cylinders.

[trikebubble]

The areas circled in red note the location of the loose hose clamps on my old Vulcan 2000, as well as my old Mean Streak 1600. I had to physically remove the tank and upper frame section on the V2K to access the clamps. I had to remove the rear tank bolt and prop it up to access the clamps on the Mean Streak.
I tightened the clamps and all signs of drips and/or leaks went away.

[9511234]

Are these the ones on the 1500? Are you talking about the clamps on the cylinders themselves or other clamps leading to the cylinder.

Here's how they look on my 1500.

[rbentnail]

Yeah, those are the ones. Trike mentions specifically his Mean Streak and V2K but I had the same weepers on an '04 1500 Classic.

[9511234]

So- just making sure before I put the tank back on-

If I tighten those two hose clamps and the problem persists, I have bigger problems.
I was hoping to see a lot more weeping from it- but it just seems dry.

Before I put the tank on are there any other hose clamps for the coolant I should tighten, or is that it?

[rbentnail]

Ooh, it's been a while. Lessee, clamps between the cylinders, front of the rear and rear of the front were the weepers. Couldn't really see a leak just smell it. Took some talcum powder to find the traces of coolant. Clamps on the carb (n/a if you're FI I think). And just look around down in there, if there's a hose clamp then tighten it up.

[trikebubble]

I systematically went around and checked all the coolant hose clamps on the bike(s). The majority of the smaller diameter ones seemed loose and I tightened them. The larger diameter clamps (to/from radiator) seemed ok, though I checked them anyways.

[Jake '53]

I had a problem with the pressure cap. Got it in cocked once and had to replace it. It would not re-seat after that.

[sunshineNomad]

Had the same trouble with my '05 Nomad. I used a blacklight/coolant dye and most of the clamp areas lit up. I tightened the clamps on my V2K at 5000 miles and all is ok. Seems like a factory defect situation.

[Dudester]

This is something I just have to do. I've been smelling rad fluid for a couple of years now, yet I see no evidence of any leaks anywhere. I've never removed the gas tank before, which is why I haven't tightened all the hose clamps underneath the tank.....yah, I know, I'm a big chicken. However, if someone could send me a link, with visual step by step explanation on how to remove the gas tank I just might give it a try once it warms up here. I'm tired of getting that smell, and something must be done. I keep checking my rad overflow bottle, which at times is a tad low, but hardly worth mentioning.
Great thread, and I look forward to reading more about this Kaw problem. BTW way, I ride a 2003 Vuclan 1500 Carbed.

[S.D.Willie]

same issue on my 06 1600 classic. Not visible but you sure can smell it. Will take the tank off when the weather gets nicer and have at this b*tch.

[Dudester]

Bump

[Turbojoe]

I just did the 6,000 mile service on my 2004 Vulcan 500 yesterday. Though the reservoir never got low at all I've been smelling coolant since I bought it last month and could see a very small white trail down by the hose running from the bottom of the radiator to the water pump. I planned to replace that hose during the service. When I pulled the fuel tank off it was easy to see that the problem was actually at the hose to the coolant pipe in the top of #2 cylinder. The clamp just wasn't tight enough and the coolant was seeping out there. The spark plug area drain hole is right over the water pump so that's why the coolant was ending up down there. I went around and tightened all the clamps including the ones "hidden" by the fuel tank. After several test rides there is no more smell and everything is bone dry.

Joe

[Dudester]

I just did the 6,000 mile service on my 2004 Vulcan 500 yesterday. Though the reservoir never got low at all I've been smelling coolant since I bought it last month and could see a very small white trail down by the hose running from the bottom of the radiator to the water pump. I planned to replace that hose during the service. When I pulled the fuel tank off it was easy to see that the problem was actually at the hose to the coolant pipe in the top of #2 cylinder. The clamp just wasn't tight enough and the coolant was seeping out there. The spark plug area drain hole is right over the water pump so that's why the coolant was ending up down there. I went around and tightened all the clamps including the ones "hidden" by the fuel tank. After several test rides there is no more smell and everything is bone dry.

Joe

Hey way to go Joe, you beat me to it. I will be doing mine as soon as I have a free moment to concentrate on getting the task done. I have bee procrastinating enough, so this week, I'll try and git er' done. I know the problem is just a few loose clamps, but I've been a little scared of removing the gas tank, but I'm now determined, it's gotta get done, and I must stop putting it off. I'll report back once it's fixed, and I'll try and post some play by play pictures as I do it, to help some other poor procrastinating sap with hope that it will help them out and give them the confidence to do it.
I'm also on the verge of replacing my motorcycle rear tire for a car tire, but that's another thread and discussion.
Thanks for posting the results you got. Welcome to the forum and safe roads.

[Turbojoe]

It took me less than 5 minutes to remove my tank for the very first time. One 8mm bolt on the instrument panel. Lift it up and disconnect the speedo and two electrical connectors and the panel is off. One 8mm bolt to remove the seat. Two vent hoses on the right side of the tank, one vacuum hose and the fuel supply hose on the left side, two 12mm bolts and off comes the tank. Easy as that. At least on my 500.

Joe

[Dudester]

Thanks Joe, I know once I do it, I'll be kicking myself for having waited so long....DOH !
On my 1500. the procedure is a little different than your 500, but basically the same.

[thechaz05]

Help I too have a coolant leak but not from a hose, I wish it was that simple. I have a 95 vulcan 800 and I just noticed that I am leaking coolant from the pipe going from the top of the Right Engine Cover to the Crankcase. It's leaking from where it goes into the crankcase. It appears to be a seal issue but I am leary of taking off the cover (only way I can see to remove pipe) as I do not know what all I will need to replace if I do. I have the service manual but it is useless. It shows an exploded view, but no part numbers or descriptions or what needs sealant and so forth. Please help.

[Dudester]

Sorry Chaz, can't help you with your question, but I'm sure some of the more mechanical guru's here will chime in soon.
In the mean time, here is a thread that I added some pictures on how to tighten the rad hose clamps, and removing the gas tank.
http://www.kawasakimotorcycle.org/fo...se-clamps.html

[BlkSteele]

I have the same issue with My Vulcan 900. I am noticing leakage from around the clamps. I have to find a way to loosen the tank, so that I can get in there and tighten the clamps. The owners manual is no real help. If any one knows how, please do share.

[trikebubble]

I have the same issue with My Vulcan 900. I am noticing leakage from around the clamps. I have to find a way to loosen the tank, so that I can get in there and tighten the clamps. The owners manual is no real help. If any one knows how, please do share.

I'm not sure how to loosen and/or remove the tank on the 900. Post a question in the cruiser thread about "900 tank removal" or something like that, and I'll bet you get the help you need.