ER6 blowing coolant

[7clubs]

G'day from a noob,

Straight to the point. Yesterday at Eastern Creek, my ER6 was blowing coolant out of the cap of the expansion reservoir. The overflow pipe was not blocked, the coolant level was correct when cold and the cap was secured properly. I now have lovely streaks of coolant over the right side of the bike. It has always had a hot smell, even after a fairly modest road ride, but I have never seen the temperature warning light, nor has the coolant ever boiled. Any ideas as to what's going on? The bike is less than a year old, so I may take it to a dealer for a looksy, that's what the warranty is for. I bought the bike from Richard at Narellan Kawasaki, which has now closed, a shame as he was a top bloke. Any recommendations for an official Kawasaki dealer who won't screw up my bike in Sydney? I'm thinking Flywheels, as I wouldn't mind getting a dyno run at the same time, to dial in my Power Commander, but know nothing about them.

Great site, by the way, but where are all the ER6s? You are missing out on a top little bike, it just needs a little fettling. More of which later.

Thanks for any help,

Richard

[Neka79]

Richard and Narrellan Kwaka was a sponsor here i think...and Flywheels are too, so im sure they can help u... i will read this thread with interest, cos my zed is doing the same thing- well not overflowing, but running FARKING hot..were talking almost always over 105deg.. admittedly its been hot lately...u think the hot weather may of caused it??

ive taken my bike back twice to complain abt it running hot..they reckon the coolants fine, theres no prob with blocked hoses or anything like it...

the only thing i can think of..is the thermostat is stuffed..but the bike's brand new.... im out of ideas...

[Barrabob]

The core of the radiator can clog with road muck and a garden hose will get it out (external) just dirt and the like so see if you can see daylight through the core and if not hose it out.

They will run at 105 degrees at idle but around 70 when running.

[MickLC]

If your temps are OK it might just be a problem with your radiator cap...they are usually the first thing to start playing up and are cheap and easy to replace

[billwest]

Maybe you need to bleed your cooling system - there may ba a large air pocket in there, pushing the fluid out via the overflow.


Had this on the ZZR1200.

Bill.

[Slow and wobbly]

If your temps are OK it might just be a problem with your radiator cap...they are usually the first thing to start playing up and are cheap and easy to replace

It does seem strange though that 2 newish bikes are suffering similar probs.
Some workshops have a tool that will test rad caps for they're ability to hold pressure. Walk in cap in hand ( no pun intended ) and see if they can do it for you. At least they may be able to rule it out. As opposed to buying another genuine part that suffers the same prob.

[Possum]

Hi All,

I'm newby to this site! I upgraded from ER5 to ER6 in Feb this year. Hope this helps.

SUBJECT: Blowing Coolant

ER5 - Blew coolant on a 800km ride. The problem was: The where the water pipe fits the head there's only one bolt and an o ring. The one bolt allows the pipe to viabrate with the bike and destroys the o ring, hence the leak.

ER6 - Started to leak on the way back from the Moto GP. (It had just had it's 12,000 service the week before!) I had noticed it was getting unusally hot, but they found nothing on the major service. Now she's leaking, but I'm not sure from where. I'm pulling her apart this weekend (check you dont void your warranty)
I suspect it's either an o'ring / thermostat or (i bloody hope not) head gaskit.

THERMOSTAT TEST: Take it out, put it in a pot of water and boil it to 120 degrees. It should be fully open. If it only half opens, pitch it and get a new one.

PLEASE NOTE - If your bike gets unusually hot get it looked at immediately, because if the temp light does come on your bike is cooked.

I'll post a message on Monday letting you know what i find. I'm also contacting Kawasaki to find if there are any issues with new ER6's released this year.

Cheers Happy trails

Possum
'Bike Mechanics Daughter'

[Gosling1]

nice post there Possum......ER5/6 owners - Take Note.

[Waldorf]

Slightly off-topic..

I didn't think you were supposed to run coolant on the track - only water?

[7clubs]

Slightly off-topic..

I didn't think you were supposed to run coolant on the track - only water?

On a track day, the organisers don't insist you flush your coolant and run pure water, at a race meet, it would be compulsory.

Possum, with regard to my bike blowing coolant out of the reservoir cap, I spoke to the mechanic I always use and trust implicitly. He reckons that it is a common Kawasaki trait and recommended running the coolant level at the minimum mark on the reservoir when cold, rather than close to the maximum. Having followed his advice and having done half a track day at Oran Park on Saturday, I have had no more issues. So I'll think optimistically and assume there is no other problem causing the blow-out.

On a different note, it is great to see some other ER6 owners coming out of the woodwork. You don't see many of these bikes around, but with a change of bars (as per another post) and ideally better suspension and brake components, it is a giant-killer.

[Possum]

Thanks for the tips - I'm keen to find out what the issue is - I'm hope that's all it is...will let you know on Monday when I get a chance to have a look.

I took note of that other post and I’m interested in the new bars and some cosmetic stuff at the rear, but tell me more about what you’ve done with the suspension and breaks?

Cheers Possum

[Possum]

After all that talk it was just a faulty hose... it's strange because the bike was new in Feb this yr. -upon further inspection the hose was thin in the area that split...- but i don't know how that is even possible. My dealer says it's a manufacture fault.

I haven't heard back as yet from Kawasaki - re: this years ER6's faults... but i did find this while surfing:

ER6 CRACKED FRAME : Kawasaki attributed the problem to a gap between the engine and frame bracket which pinches closed when the bolt is tightened, placing stress on the frame tube when the bike viabrates.

Ride safe
Cheers Possum

[6maniac]

Appears Kawasaki have addressed the frame cracking problem by beefing up the bracket welded to the frame on the '07 models.