Flattened radiator neck

[mushroom-season8711]

I did something stupid while doing some maintenance on 21 KLR650. I was checking valve clearances and they were just barely within spec, thought I can swap some new shims.

It was all good until I tried pulling the valve cover. I ended up draining the coolant and pulling the upper radiator hose which was stuck so I twisted it a little and you guessed it, the radiator neck was flattened. Didn't realize that metal was soft?? Anyone know a good way to make sure I don't get leaks when I put it back together?

 

[DesertRider650]

Oops, that's an easy thing to do, these necks break easily. You can probably bend it back carefully. Then, you could use JB Weld around where it broke, or slide a copper tube inside the neck to keep it in place with strong glue. Just make sure it's clean before you seal it up.

Are you going to try and fix it yourself, or take it to a pro?

 

[klrtrailwolf1022]

I did something similar years back with my old XT. I barely twisted a stuck hose and ended up crushing the neck. I had to use a copper pipe sleeve and some JB Weld, and it actually held up well for years. Those radiator necks are way softer than you'd expect

 

[Ohwhen]

I believe you can carefully reshape it with a deep socket and gentle persuasion, wrap the socket in tape, work it into the neck, and twist slowly to bring it back round, then use a good quality hose clamp and maybe a light smear of silicone or gasket sealant around the outside of the neck..not inside the hose to seal it all up