Coolant Disaster

Keshyoma · Post by **Keshyoma** » 05:51 pm Mar 21 2017

Hey guys, in the ongoing saga of repairing my 91 kdx, things have taken a horribly wrong turn. I thought i had everything reassembled right (after a top end rebuild), went to add fluids, and lo and behold coolant flooded into the cylinder, carb, exhuast and crankcase. I know I know, I screwed something up big time. I didn't use a gasket sealer on the main gaskets, thats probably part of it. Anyways, I'm trying to drain a gallon of coolant from everything and the only thing I cant figure out how to drain is the crankcase. I thought it was through the oil drain plug, but that doesnt seem to be the case. Can someone point me in the right direction? I'll get a picture up here shortly.

I found out it wasn't a mistake in assembly, theres a crack in the head on the outer portion of the KIPS valve allowing coolant to seep through the water jacket.

Keshyoma · Post by **Keshyoma** » 05:59 pm Mar 21 2017

Here; How the heck do I drain this??

Dekon · Post by **Dekon** » 06:10 pm Mar 21 2017

The picture isn't showing, but someone else on here had that issue(if it is a crack under the KIPS cover on the left hand side).

Here's the link, there are pictures about 1/2 way down the page.
http://www.kdxrider.net/forums/viewtopi ... ak#p181100

Keshyoma · Post by **Keshyoma** » 06:33 pm Mar 21 2017

Yup, I have a crack in the exact same place, that is EXACTLY what happened as in the thread you linked. Ill end up taking it to a machine shop and asking a pro to weld it, but man am I upset.

Post by **KDXGarage** » 07:10 pm Mar 21 2017

No sealer on the gaskets

Turn the engine upside down and drain or a syringe and house, paper towels at the end

doakley · Post by **doakley** » 09:02 am Mar 22 2017

Put the mag cover back on first. No need to soak the electrics with antifreeze. You might want to flush the crank case with something to displace the coolant. Premix should work. Not a big deal. No more mess than if you drowned the engine in a creek. No harm.

TheGriz · Post by **TheGriz** » 08:49 am Mar 23 2017

x2 on just turning the engine upside down to drain it. I don't use sealer on the top end.

Curious about your crack. You mentioned that the head is also cracked? So, the cylinder and head are both cracked? Is it cracked on the inside also? Just wondering how the coolant got into the cylinder.

BTW - That link was to the rebuild of my 91. I feel your pain. Can you show us pics of the cracks?

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