Coolant Leak problem

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TheImp · #1 Unread post by **TheImp** » Sun Nov 19, 2006 10:36 am

Hi everyone, it's been a while since I've posted on here, I've been so busy.

Some of you are aware that I have a Kawasaki Vulcan 500 thats only a few months old. Today I decided to take my bike for a ride after its been sitting for about a month. However after I started it up and got it warmed up I noticed coolant was leaking from the engine. I looked closer and it was a slow leaking from a existing hole in the middle of the engine block on the left side. I wasn't too sure what the hole was for but perhaps it has some kind of pressure relief valve within it? In other words perhaps I overfilled the coolant and its supposed to leak from there? I don't have my shop manual with me right now to check the troubleshooting section, so I'm hoping that someone here can let me know if there is something serious going on. The exhaust isn't giving out any weird colored smoke and I've ridden the bike quite a few times since I've last filled the coolant, the only thing is that it was sitting for about a month so I have no idea if that means anything.

I appreciate any insight anyone can give me as to whether I have a serious problem on my hands or not.

EDIT: Also, the hole thats right in the middle of the left side of the engine block is very small, smaller than the size of a dime that was machined into the block. I really need to find out what the purpose is for that hole...I'm getting worried..

EDIT2: Here is an image of the exact year and model of my bike I got off of bikepics.com. I have a circle I drew around the hole I was speaking of. If you look real closely you'll see the hole. I really want to know what it is. My friend at work who also rides has no idea what it is either.

#2 Unread post by **dr_bar** » Sun Nov 19, 2006 1:10 pm

Looking at yhe schematic, I can't see anything like a relief valve...

Schematic

Doug

TheImp · #3 Unread post by **TheImp** » Sun Nov 19, 2006 1:20 pm

That's the vulcan 2000 you're looking at. The one I have is the 500 and indeed I checked out the schematic online at the same site earlier today.

This is the schematic

This is insane. I have no idea what is going on. The water or coolant jacket that surrounds the cylinders would be below that hole, correct? I'll have to run the bike later but I really did not find any colored smoke. Now a few months ago I did drain and fill the coolant as part of the steps in adjusting the valves. But assuming I overfilled it, it shouldn't be a problem now I would assume. And if it was indeed an overfill issue it should be leaking out of the reservoir...

#4 Unread post by **dr_bar** » Sun Nov 19, 2006 1:45 pm

I'd throw this one in the trouble shooting forums...

TheImp · #5 Unread post by **TheImp** » Sun Nov 19, 2006 2:14 pm

You know I think I know what the problem is. There is a cylindrical shaft that is screwed into the cylinder head down in a well thats at the top of the cylinder head. This shaft is a channel for the coolant to go through the block. I think I did not screw it in tight enough because it was a "dog" for me to get out the first time so I lightly screwed it back in after my maintenance. It's likely that the leak is coming out of the bottom of the shaft and is channeled out by that hole in the head.

I'm almost willing to put money on it that it's the problem. This is a very weird occurrence that has no simple explanation so it's likely my screwup rather than the bike itself. I'll probably post my results after I look at it closely.

Shorts · #6 Unread post by **Shorts** » Sun Nov 19, 2006 2:21 pm

I'm staring at the repair manual now, but I'm somewhat crosseyed and not making sense of any info

If you need something from the book, post up and I'll do my best to get you the answer.

CORSCO · #7 Unread post by **CORSCO** » Sun Nov 19, 2006 4:50 pm

Are you sure it was coolant and not water. That hole goes to the spark plug cavity so moisture does not pool up around the spark plugs. The opposite side should have one as well.
Is there a coolant hose that goes to the top of the head, around the spark plugs? Maybe that hose is weeping and running into the plug cavity?
If not, head gasket which is rare but not impossible.
Good luck.

If brand new, take back to dealer.

scan · #8 Unread post by **scan** » Mon Nov 20, 2006 2:08 am

Moved this thread to troubleshooting.

Wed Dec 06, 2006 4:16 am

My bike 82 xz550 has a few weep holes that run along the cooling system to let you know if a seal has failed. If it comes out certain holes it's indicative of a problem in that area. Might be something to look for in your manual or ask on a vulcan forum.