Author Radiator leak  (Read 33788 times)

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  • Offline nasosrr   se

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    Offline nasosrr

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    Re: Radiator leak
    Reply #20 on: 06 June, 2023, 10:36:22 am
    06 June, 2023, 10:36:22 am
    Last Saturday I completed the installation of the new radiator. Got tons of help from Art's instructions and advice and of course I wouldn't have made it without the manual and Haynes book.

    Here is the process I followed (tried to make it short and removed all the boring parts):
    (the video is unlisted, I am just posting it here)

    And here is the lady, after the reparation was complete:


    And some pics, before, during and after:
    https://ibb.co/album/tMZ3fb

    I still feel a bit nervous when I ride, because I am worried I didn't complete the air-bleeding process correctly, but on the other hand, I drove for like 50 km yesterday and everything felt normal. And the radiator gets warm, as it should, so it seems to me that the coolant circulates properly everywhere.

    One thing I am not happy about, is that I didn't flush the system properly before I re-filled it. I should have done a better job there. The reason why I didn't, is that I don't have access to running water at my garage and I had to carry bottles from my apartment. So I only flushed it with about 2 liters of water, but yeah, I see that the coolant in the reserve tank isn't very clean already. :(

    I get restless when I take down panels and get access to stuff and I behave like a child, "Ooooooh, can I remove this one too??? Cool!!!", so I took the opportunity and cleaned up a little bit down there too. It's far from mint, but it's better than it was before.
    I also noticed that the cables for the heated grips had started wearing off a bit (thankfully only the self-vulcanizable tape that I had wrapped them in), so I found some plastic tube and wrapped it around. I couldn't find a larger diameter though, so it doesn't look pretty. But I am still looking for the right size and once I find it, I will replace the nasty parts down there.

    One question?
    As you can see, I covered the headlights' contacts in plastic bags, to protect them from dirt. Is there any reason why this is a bad idea? Risk for catching fire or anything?

    That's it from me for today folks.

    Once again, thanks a million!!!  :020:

  • Offline Art   england

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    Offline Art

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    Re: Radiator leak
    Reply #21 on: 06 June, 2023, 12:28:07 pm
    06 June, 2023, 12:28:07 pm
    Happy days.

    Bleeding the coolant - After re-filling the system surround the filler neck with rag to catch any spillage, run engine up to normal operating temperature, blip the throttle two or three times, switch off and top up to filler neck, replace filler cap and allow to cool. Once cold top up expansion (reservoir) bottle to upper level, check level after 100 miles.

    Completely draining the system is difficult if not impossible. What I do is drain as much as will drain from the coolant drain plug which will be about 2 to 2 litres which leaves to 1 litre in the system. To flush I then refill the system with de-ionised water, bleed the system without topping up, allow to cool and drain again. I repeat this process once or twice more until the drained fluid is all but clear. To achieve a 50:50 mix of coolant:de-ionised water on the final fill I first add 1 litres of concentrated coolant and top up with de-ionised water. Which is why I prefer concentrated over ready mixed coolant.

    Covering any electrical cable with plastic bags or PVC tape is a bad idea because it can cause the cables to sweat and over heat. There is also a risk of water or moisture  ingress and once water or moisture has found its way in it can't get out. The solution is simple use a propriety automotive cable sleeving, if its just to protect from chaffing spiral sleeving can be fitted without the need to disconnect the cables, if tubular sleeving is used do not seal the ends which will allow any water or moisture ingress to escape. If you need to tape cabling use a wiring harness tape.

  • Offline nasosrr   se

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    Offline nasosrr

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    Re: Radiator leak
    Reply #22 on: 06 June, 2023, 01:06:41 pm
    06 June, 2023, 01:06:41 pm
    Man, you really are a living library of invaluable information!
    People like you, in all kinds of professions, are the reason why internet is SO amazing! Really REALLY thank you!!!

    I'm going to the garage now to remove the plastic bags.

    Next time I replace the coolant (which will be a bit sooner than I otherwise would, now that I know there's something bugging me) I will certainly follow your process. :)

    And, like I said many times before: Thanks a lot!  :031:

  • Offline WileyCoyote

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    Offline WileyCoyote

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    Re: Radiator leak
    Reply #23 on: 23 October, 2023, 04:37:43 pm
    23 October, 2023, 04:37:43 pm
    Help &/or advice respectfully requested.  :012:
    Checked the radiator expansion bottle the other day, following a ride of 120 miles, before putting the bike away.  Was concerned to find it was empty, or very low at least.  A visual check around hoses and radiator showed the tell tale dried out coolant spray over exhaust headers and surrounding area.!   There appears to be a leak from a split in the lower left hand side of the radiator.  Not catastrophic, as we made it home without any untoward indications, including temperature warning light.
    Anyway,  encouraged by all the foregoing in this very useful thread, decided to remove the radiator for probable replacement.  Drained the coolant to find there was only about 2 litres remaining.  Eventually managed to remove the three hose connections to the radiator. First time in 14 years, since new, so they were a little stubborn but couldn't withstand the onslaught from the wife's hairdryer.  (still not forgiven for leaving it on the garage floor !)

    Now the bad bit,  try as I may, I have not been able to "Unsnap" the connector from the fan motor.  Despite heat and WD40 it won't budge.  Can't tell if the tabs should pressed in or lifted up. Either way they won't seem to budge.  Your expert advice(s) would be gratefully appreciated.  :037:   Draw string already around the cable, by the way,  thanks Art.
    Bike is a Mk1, 2009 reg.

    Oh, one other thing, do the grommets locating the bottom edge of the radiator require any special attention or will they simply "pop" out when pulled ?

    Probably overlooking the blindingly obvious so please be kind.

    Very many thanks .

    Paul.

  • Offline Art   england

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    Re: Radiator leak
    Reply #24 on: 23 October, 2023, 06:39:26 pm
    23 October, 2023, 06:39:26 pm
    Tabs? There is only one tab and its on the fan motor side of the connector between the two terminals, the slot being on the loom side of the connector. I ease them apart by placing a small flat blade screwdriver between the two halves of the connector where the tab is between the terminals and gentle lever the slot outward and the connector halves apart.

    Here are the two halves disconnected.


  • Offline WileyCoyote

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    Re: Radiator leak
    Reply #25 on: 23 October, 2023, 07:04:28 pm
    23 October, 2023, 07:04:28 pm
    Thanks Art,  will get on it in the morning,    :028:

    Cheers,

    Paul

  • Offline Art   england

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    Offline Art

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    Re: Radiator leak
    Reply #26 on: 23 October, 2023, 07:05:12 pm
    23 October, 2023, 07:05:12 pm
    Your welcome, not sure I understood the grommets question. The radiator is secured by two bolts at the the top and two pegs/grommets at the bottom. To remove the radiator, after dealing with the plumbing and electrical connections, remove the two top bolts, tilt the top of the radiator forward and slide the radiator to the right off the pegs. The rubber grommets remain on the radiator but can be eased off easily, when refitting give the grommets a smear of silicone (white rubber) grease.
    Last Edit: 23 October, 2023, 07:05:47 pm by Art

  • Offline WileyCoyote

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    Re: Radiator leak
    Reply #27 on: 24 October, 2023, 07:06:02 pm
    24 October, 2023, 07:06:02 pm
    At last,  connector parted,  radiator on the bench after giving the rear of the fan motor and housing a good brushing off.
    Now need to order a replacement radiator, avoiding Honda's supposed "OEM" option, and get it all back together again.
    Triple QX Red Concentrate already waiting on my shelf.  The connector was a right stiff old bugger but it came apart eventually and looks perfectly serviceable for further used as do the rubber grommets.   :152:

    Thanks so much Art, I was almost at the point of cutting the cable and putting in another connector. (bodge, I know). :182:

    Cheers,   :031:

    Paul.

  • Offline Art   england

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    Offline Art

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    Re: Radiator leak
    Reply #28 on: 25 October, 2023, 05:32:14 am
    25 October, 2023, 05:32:14 am
    Happy days

    Give that connector a smear of white silicone grease inside and out before re-assembling, use it on the rubber grommets too if you don't have any red rubber grease to hand. Note errata in my previous post red rubber grease for grommets, 'O' rings etc and white silicone grease for electrics although no harm in using both on rubber.

    Here, never used them but DRS Heat Transfer must be fairly local to you and worth a phone call/visit to see if they can repair.
    Last Edit: 25 October, 2023, 05:48:45 am by Art

  • Offline WileyCoyote

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    Re: Radiator leak
    Reply #29 on: 25 October, 2023, 02:53:56 pm
    25 October, 2023, 02:53:56 pm
    Hi Art,
    Thanks for the referral.  Phoned DRS but they were unable to offer repair services at present. Always worth a try though.
    Anyway, have ordered a new one from Motorcycle Parts Warehouse down in Brighton who say they have some in stock and should deliver it by this Saturday.  No doubt it will be of Chinese origin but at least the seller is UK based.  Made use of extra "insurance" via eBay, Paypal & credit card.  We shall see.

    Thanks again, just looking out my tin of silicone grease.  :028:

    Cheers.

    Paul.