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Coolant manifold help

M

meemuh

Guest
Guest
Anybody have any tips on successfully installing the 4 inlet coolant manifold on the front side of the engine. I put everything back together on my 2000 tonight...the o-rings held until about 30 seconds after I shut it down...then the two left rings (petcock side) blew out...spraying coolant all over. I'm sure it's just a matter of how they were installed... I could really use some ideas - so I don't have to do this a dozen more times... Thanks
 
Sure #1 you MUST use new o-rings these suckers take a lot of grief. #2 clean the port that the manifold plugs into with scotch-bright or 400grit emery paper. #3 Clean well the manifold again with 400 grit to make sure its not pitted or rusted. Consider a light spray with black enamel #4 lightly grease the o-rings, and the head ports with grease and install the o-rings on the manifold #5 gently push the manifold into place the lube of the grease makes it easier and less likely to pop the o-ring out of the grove. Push it in parallel not all one side in first #6 make sure the manifold snugs up to the block and then install the 2 small screws and snug them down. #7 have a beer or a cup-o-tea The used o-rings are totally flattened out and elliptical in profile, where as new ones are round. Hence if you try to re-use them they will fail. I have tried using generic o-rings from Harbor Freight but they failed. So now I buy the pucker ones from Kawasaki as for 30Cents each its not worth messing about.
 
Is it possible to do without remove the exhaust? Space is a little tight behind the header....but, geez.... I'm afraid I know the answer...
 
Is it possible to do without remove the exhaust?
Click to expand...
Umm... good question. I'm 95% certain its not possible. If you are going to order up the o-rings, your best to order up the copper exhaust washers as they flatten on use, and the chances are they will leak if you re-use them. I have reused them in the past, sometimes they work other times not. As its a real PITA to replace them better to buy new and save the risk of the exhaust leaking.
 
Actually - I did manage to remove and re-install the manifold w/ the exhaust still on...but it sucked. I invented new words - and the rings blew out. Just can't get a good, straight on push on the manifold on - I guess. Ordering rings, copper washers, etc. this afternoon...oh - the joys of being too cheap to pay somebody to fix it for me.
 
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