[treblhooks]

After reading the expert advice here I finally got rid of the dreaded anti-freeze smell on my '05 1600 classic. Hose from radiator up to the cap took right at 5 complete turns to tighten up. That was definately where my odor was coming from. Actually had a green trail running down and it was all crapped up around that hose. The other hoses took a little snugging but were basically good.
Dudester, like you, I was a little skittish of trying to remove the tank that first time. I took my sweet ever-lovin' time so I didn't screw up too bad and still only took me about 30 miinutes to yank the tank, tighten every hose I could find and put the tank back on.
Thanks for the advice and how-to guys.

 

[gak]

Has anyone had this problem? The rubber dampers that hold the radiator in place become worn, wallowed out, allowing the bottem front of the radiator to move forward slightly, causing the drain plug bolt/nipple to rub/vibrate against the crash bar and create a stress crack on the drain plug nipple at the base of the radiator. This is a 1600 vulcan classic.

 

[GelBand]

I have a 2007 Vulcan 1500 F1 Classic. Currently has 4,600 kilo (2400 miles) and I have had this leak since I bought it. I never drove much and originally there was not enough of a leak for them to find anything. The little riding I did do, I was always able to smell antifreeze but did notice on the crank case on the cylinder facing back of the bike a couple drops of glycol. I took it in for a service and to have the dealer to look and replace the faulty gasket. To my surprise, I received a call today that this gasket replacement was going to be a 14 to 15 hour job at $115. per hour. So, they stopped the work and only did the maintenance and called to break the news to me. Apparently they would have to pull the frame apart, pull the engine out and replace the back water gasket. Sine I hardly ride, of course I was very disappointed in have to spend up to 2k for what appeared to be maybe a $200 to $300 fix. I was tempted and still contemplating on buying a new bike but was really looking at something different and not a Kawasaki brand. I came home very disappointed and left the bike at the dealership. They are trying to get me to look at the 1700cc's (Nomad or Vaquero). While not getting much for a trade in was disappointing since low mileage and has never been outside other than during a ride (it sits in my garage). I started to search on the net and came across this forum. As I went through I have experienced exactly what each of you have posted. I am going to pick the bike up tomorrow (if it does not snow as they call for), and going to try and pull the fuel tank and see if I can get at those hoses. My other disappointment is that, as a dealer you would think they would be aware of this common issue of loose hoses. My question anyone is, if in fact it is not a loose clamp, would Barrs Leak work or is that a no no for bikes? I cant also see how it would take 14 hours to pull that all apart for an intake gasket but I am taking their word for it. I will try what has been explained on these links and hopefully this will save me a new bike. I will say, my wife and I have grown fond of the 2012 Honda Goldwing but that will depend on the success of the hose clamps. Thanks for any input or advice. I just find this disappointing!

 

[Turbojoe]

GelBand,

Go after those clamps! I'd bet dollars to doughnuts that's where your problem is. I'd hate to think the dealer is trying to rob you but it's always possible. If it is the clamps then you can spend a little time and save yourself a ton of money. If that doesn't fix it then go for the Barr's leak. Just use a VERY small amount because your cooling system is a tenth the size of a car system. I have a PT Cruiser that was seeping from the thermostat housing down on the block. EVERYTHING under the hood of this car is impossible to get to so I put a bit of the Barr's leaks "Liquid Aluminum" in and it did the trick. No more leak. As long as you don't pour the entire bottle in the bike it should be completely safe but only use it as a last resort. Remember it's just a band aid.....

Joe

 

[Slots]

Yep..... my 2006 Nomad leaked from all the undertank hoses you identify. I sure do like my Nomad but one must wonder at the complete blank-headed engineering/assembly skills that have produced the same friggin' leakage problem year after year....model after model. Same kinda cement heads that consistently produce bikes with that damned headlight rattle....weak clutches and even worse...engines that ping worse that a Chevy diesel truck.

Thanks to much help here and other boards all these problems have been fixed (by me and Guy Mobley)...the Reno dealer never would admit any of these were problems "they all do that" was his standard reply.

All is good now. Sure do love my bike, just wish Kawa engineers were more attentive to these kinda issues...and my useless dealer was worth two red cents....

Regards to you all,
Slots

 

[Dredd1]

hello i have the same prob. as you i have a 98 Vulcan 800 leaking in same area as chaz from the rear of the cyl. to the crank case. was wondering if you figured it out thanks

 

[ElectricMojo]

Gettin ready 2 bust into mine for minor leak thats been there for a few yrs.Not a problem just got the smell and loose maybe 2 cups a yr.Dont slow it down any !!!!

 

[reddwar]

When it gets around 100 or more which it is now doing I just started hearing a whistle when I turn it off like when your car is over heating. Put antifreeze in her & did not take very little. I will tighten up the clamps hope that will take care of the whistle.

thanks red

 

[Box]

The whistle is generally just expanding air escaping from the gas tank.
It happens on most bikes as they heat up.
I remember someone here referred to it as the bike simply whistling it's happiness to be out in the sun, or a thanks for the ride whistle as you walk away.

 

[rbentnail]

The whistle is generally just expanding air escaping from the gas tank.
It happens on most bikes as they heat up.
I remember someone here referred to it as the bike simply whistling it's happiness to be out in the sun, or a thanks for the ride whistle as you walk away.

Yeah, I've been hearing that from lots of bikes lately. A 1500 the other day was just as happy as they come!

 

[Dudester]

Geland
Just tighten the hose clamps (all of them) and I'm almost 100% sure, your problem will be solved. It's not hard removing the gas tank, just take your time, and have thick blankets handy not to scratch anything. Once you will have done it, you'll realize how easy it was. If I were you, I would find another dealer to work on your bike.
Good luck.

 

[ronnie]

I've got an o6 nomad. One of the lower welds on the fitting on the bottom of the radiator started leaking. Fortunately it had about 15 days left on the warrenty, and my dealer, where I purchased the bike new, replaced the complete radiator with a new one. About 3 weeks after that, the clutch went out. But, don't guess i can complain too much, as it has almost 100 thousand miles on it. ronnie

 

[rbentnail]

I've got an o6 nomad. One of the lower welds on the fitting on the bottom of the radiator started leaking. Fortunately it had about 15 days left on the warrenty, and my dealer, where I purchased the bike new, replaced the complete radiator with a new one. About 3 weeks after that, the clutch went out. But, don't guess i can complain too much, as it has almost 100 thousand miles on it. ronnie

100K on the clutch? Well, I'd say you got your money's worth on that one. But the radiator is a new one to me. How often did you change the coolant? What brand(s) did you use?

 

[ElectricMojo]

Thanx to you all for your feeds.This is the ONLY problem I've ever Had with my Vulcan Classic.I just change the rubber & brakes & keep the fluids in'er

 

[topit]

Hi guys
I have owned two kawasaki vulcan classics now a 1600 and a 2ltr. Both great bikes and both developed coolant leaks which were hard to find they were that small.
Both were leaking from the lugs on the bottom of the radiator where it is an obvious weak point. A mate of mine with a 1600 same problem. A pain but an easy fix take the radiator out a twenty minute job and give it to a radiator specialist. A pain for them to repair because the metal is so lite but it can be done

 

[Blooze]

My 1500 leaked a very small amount for several years after I got it. Finally took it in under warranty and they see med to fix it. Last year right before the warranty ran out it was doing the same so again I went in and had them check the clamps. They said it was just the one on the left side where it connects to the back of the front cylinder. I only got to ride it a couple of times after that but all seemed well again. I just pulled the bike out of storage this weekend and noticed the coolant level was a about halfway to the full mark on the overflow tank. I didn't see any of the tell-tale leak signs anywhere. Took it for a short ride, never smelled anything, and parked it till a little while ago. I just went and pulled the air filter housing off a bit ago (noticed the coolant level was at the bottom of the tank) and sure enough that hose connection was all gunked up. Cleaned everything off as best I could and tightened the clamp up again giving it a fairly good crank but not excessive I think--I don't know because I really suck at any mechanic duty). I'll need to get some coolant to top it off. Can you overtighten the clamps? And I'm beginning to think that the dealer just topped off the coolant and told me they tightened them. I'm beginning to think that with all the issues these bikes have with leaking coolant that I'd wish I had bought an air cooled bike. I'm going to be going on my first real tour this summer and the last thing I want to worry about it the dang coolant.

edit: Went back out and put the socket with extension (without ratchet) and was able to loosen the clamp slightly. I then hand tightened the clamp, then put the ratchet on and gave it about 1/4 turn more. I hate to overtighten. Guess I'll see where that leads.

Here it is all done. The whole intake the hose attached to was completely covered with dried coolant.

 

[VulcanDrifter]

Hmmm:

I've got some magic disappearing coolant on my 01 1500 all of a sudden. I've had it since new and have about 65k Kms on the bike and never had a coolant leak before. I can't smell anything, the oil is fine and I can't detect any leaks anywhere. Went for a 600 km ride yesterday and this morning the tank is down about half a cup from where it was when it was cold yesterday morning. I guess I'll have to get in there and tighten the hose clamps but if it's leaking, there's no obvious evidence. I found a post online about some older model 1500 A's where the mechanic seal weep drain is under the motor, is that the case for the later model 1500's. If so, maybe I'm leaking only when I'm riding?

 

[vulcan1500s]

i have the same bike 2003 vulcan classic two maroon with grey and the same problem. bike has 4000 miles. when a warm day comes or above 20 i will attempt to take tank off this is a good forum just registered.had two harleys sold thyem both 4 kids college tuition. bought the 1500 with 2400 miles love the bike no regrets. let me know how you made out with yours thanks john

 

[SteelCityVROC]

I've been smelling antifreeze for at least the last 2 years. Last year I did as you all said and tightened down the clamps. I still smelled it, especially at stop signs and red lights. My buddy and I looked at everything a couple of days ago and replaced the rubber grommets at the frame and placed the radiator back in. I guess the good news is I was still at his place and not 300 miles from home because all of a sudden it looked like Niagara Falls in his driveway after I started it up. Ran out of daylight so I rode his Gold Wing home (sure not used to that bike!). Anyway, for grins I called a Kawasaki dealer who told me a new radiator is $442. That motivated me to get over there today and pull it off and look again. Well, we found the problem. Chalking it up to poor design. Used JB Weld and so far so good.

 

[Cynjut]

That might well be a design issue, but there's definitely a dent in that tank near that tear. I'm pretty sure the factory didn't do that.