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Discussion Starter #1
I have been having an ongoing mysterious coolant leak/mild heating (not overheating) issue. I can't seem to find an obvious leak, but it looses coolant (slowly, but none-the-less). When I serviced it today I took some extra time and did a little investigating. I found two things.
1. The vent from the overflow tank to the ground was pinched closed/folded over in the retainer down by the clutch cover, I believe this occured when the dealer had the cover off to replace the basket.
2. When I removed the radiator cap, there was a bunch of this aluminum flake/sticky stuff stuck under the pressure side sealing ring. I believe this causes the cap to not seal propery against pressure and that allows the engine to heat up and pass coolant at a low pressure. I cleaned it up and replaced the cap. When I rode it home it seemed to take longer to heat up (good thing), so maybe I found the issue.
My question is; did Suzuki put stop leak in the cooling system from the factory? I assume they do (as most modern manufacturer's do these days), but do they use the flakes? If so, how can I get most of it out so it doesn't keep fouling the radiator cap? If the dealer did it when they replaced the clutch basket (must remove water pump too), do I raise this to their attention? I already have taken it to them for this, but they can never seem to find anything wrong.
 
R

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Discussion Starter #2
tighten all hose clamps

Don't know about the stop leak but I was losing coolant at one time. I finally caught it leaking when I had just started the bike for the first time that day and ridden a short way (100 yards?) then shut it off. (This was from my campsite to a coffee shop). When I came out there was just a few drops of coolant on the ground. A telltale white track below the thermostat housing also.

I tightened all the hose clamps and haven't had a problem since.
 

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Where did you get the info from that most motorcycle companys use a product to stop leaks in the cooling system. That stuff is designed to gum up and plug the system, thus reducing the cooling effeciency. I have used similar products as a last resort in my automobiles. Maybe I'am not up with the times, but I would be upset if I found this stuff in my bike rad.


Scooter
 
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Discussion Starter #4
Scooter,

To be honest, I'm not sure that all motorcycle manufacturer's use a stop leak in new bikes. However, most (Ford, GM, Chrysler, Toyota, Honda, etc...) automobile manufacturer's use a stop leak in new vehicles, so I assume that bike co.'s do the same thing. Most don't use the flakes though, they use the pellets that disolve. In this case I suspect that the dealer put it in when they did the basket. It wouldn't be an issue, but it keeps finding it's way under the cap and causing problems.
 
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Discussion Starter #5
In my post above, I failed to mention that while I have not been able to find an obvious leak, this time I did notice by the pattern of the dried coolant, a trail coming from the radiator cap area. The more I think about it, I'm pretty sure this has been my problem all along. The symtoms are the coolant loss and that it heats up fast (I have not let it overheat though) and would overheat if I let it. This points to pressure loss in the system. It heats up fast, but will cool back down with enough airflow.
 

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I just had my left side panel off on my 650. Noticed that they have repositioned the rad over flow in this area behind the frame. Not as convienent as the 1000 on the right side of the fairing. The over flow just has a rubber cap on it and now I'am wondering how they pressurize the cooling system.

Scooter
 
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Overflow bottles are not pressurized. It only holds the coolant that gets by the radiator cap when things get real hot in the system and expands, like when you shut off the engine. The radiator then sucks in the coolant when the system cools.
 

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Yes, of course the system is pressurized. I was mistaken. The radiator obviously has a pressure cap on it. The over flow bootle on the 1000 has a radiator style cap on it and the 650 has a rubber stopper. This is where I was misunderstanding.

Scooter
 
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Discussion Starter #9
I'm new. Mind if I ask a dumb question?

I just bought a used 03 DL1000 and I thought it runs hot. Usually 3 bars in town even if its in the 70's outside. I I drive fast enough for a while it moves down to 2. Tonight I putted around town practicing slow turns and it made it to 4 at a stop. I did have to add some coolant to the overflow tank when I bought it. Could my bike have a leak? Could the problem above cause this?
 
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Something must be wrong. Mine never goes over 3 bars and rarely over 2 and I ride in Arizona where it was 106 this afternoon. Unless you are really riding hard and using high RPM's or idiling for long periods your motor shouldn't be getting that hot.
Maybe you have a stuck thermostat.
 
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Discussion Starter #11
I'm with azsidewalker. I ride in Las Vegas and mine normally is at 2 bars with occassional 3 bars when I push it.

I would check the fan for proper operation and if that checks out replace the thermostat. One or the other has got to be defective.
 
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Discussion Starter #12
My 650 is typically 2or 3 bars. I don't usually watch it too closely but on my ride home yesterday it was 3 bars. I wouldn't worry about it until it hits 4 bars but that's just MHO.
 
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