Worlds Easiest Rad Overflow Bottle

[KXcam22]

I was building my 2nd one of these so I though I would post it as a "how to".   Total cost was $3.98 and 15 minutes. The best bottle I have found to use is the 300ml Armor-all bottle.  I looked at different ideas but found that the same one was best.  I bought a new bottle and dumped the armorall into an different one. 

1. Take the label off and wrap black electrical tape around the bottle in 4 spots. The purpose it to build up enough wraps to create a slot for the tywrap to sit. 

2. I used an old belray fork oil bottle cap, others fit as well.  Drill a hole in the cap so the hose fits loosely enough to act as a vent.  Cut the end of the hose at an angle and slide it throught he hole so it will touch the bottom of the bottle.  Retain it with a tywrap inside and outside the cap.

3. Paint the whole thing black with spray paint. To be fancy on this one I am going to mask off a thin vertical stripe so I will be able to see the coolant level through the white plastic. **** Don't use "plastic" paint.  Regular paint stayed on for years but the plastic paint was horrible and doesn't stick to this type of plastic.

4.  Install to the inside of the rad shroud (drill some holes on the inner part) with tywraps and fill about half full.

Enjoy. Cam.

[PowerFiend]

Good post.

I use a round 8oz. model airplane gas tank, but they come in many sizes and shapes. They come with a weighted coolant recovery tube, and a breather. Cost is usually about $8.

Tip: if you have too much fluid in the reservoir, disconnect the recovery tube and pressurize the breather tube. Fluid will come out of the recovery tube. 

[KXcam22]

Thats a good idea.  I am going to checkout the RC fuel tanks for future projects.  It turns out that plastic paint is not the stuff to use on the armor all bottle.  One my first one I used regular tremclad black spray paint.  Stayed on for years.  On #2, the plastic paint is not compatible, gives a horrible finish and doesn't stick. I ended up scraping it off. Cam.

[BasketCase]

Cam, did you make the aluminum guard with all the holes or is that a pre-fabed piece you bought?

[ToomanyKaws]

I bought an overflow for an 04 KDX200 and put it on my 06 KX450F.   Might put one on the 500 too.  Pretty compact and wasn't expensive.   Lid has to be ordered by iteself.    Its a good idea on any dirtbike that is going to be run hard.

[KXcam22]

Thats a good way to go (although more expessive) if they make a bottle that is close to fitting.  On my red 450, the X model bottle is really cool and mounts under the engine.  Cost me $60 but was too trick to not do it.

Basket case: That rad guard is the MSR cheap version rad guard.  Worked very well. Cam.

[The Flyin Hawaiian]

I did this on my 88 500. I put a breather line in the cap to let the air inside escape. A 89-94 KDX200 overflow will mount behind the left side panel of the 500. The 89-94 KDX200 shares the same sidepanels and would look like it came that way from the factory.

[martinfan30]

Cam, don't you have a vent of some sort on the bottle?

[KXcam22]

Martin,
  The vent is the semi-loose fit between the tube and the cap.  That is why I use 2 tywraps (inner & outer) to hold the hose into the cap. Cam.