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Discussion Starter #1
Hey Guys,


Have a 2015 Brutale 800RR that is all of a sudden having coolant come out what looks like an overflow line and I can hear the coolant "boiling" in the radiator when I shut the bike off. Was down with a dirt biking injury over the past 9-10 months and finally felt good/confident enough to at least start riding the street bike again. Went through the bike, checked all that I could, started it and let it run through 4-5 fan cycles and all was good. Then spent a lot of time cleaning it up. After that I went for a test ride for about 45 to 50 miles and when I returned is when I heard the boiling (no coolant coming out though). Next day I rode to and from work and when I got home coolant was coming out of what I believe is the overflow line. Was a hot day (90's), but the bars for the temp were only 1 or 2 past half way.


I guess my question is, while I was detailing the bike could I have knocked a connector that controls the temp reading and tells the "thermostat" valve to open and let the coolant pass through the motor? Don't want to keep riding her until I know what's up as temps are staying high out here and there was quite a bit of coolant that came out already.


Any suggestions or advise would be greatly appreciated as I really do want to ride after having to sit out almost a year now!!


Thanks
Ken
 

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No electronic component controls the thermostat...it is a thermo-mechanical device.

Most likely your radiator pressure cap is loose or degraded allowing the coolant to boil at an artificially low temperature.

However, now that the coolant has gone to saturation (boiled), there are most likely voids in the system.

Check and clean your pressure cap, then refill the system with quality coolant.
 

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Discussion Starter #4
So I found the radiator cap to have quit a bit of build up on it. Going to clean it and want to refill the system with coolant and see if that was the issue. Any recommendations on coolant? Should I drain and refill the entire system or just top it off for the small amount that came out the overflow? From what I can see, the coolant inside the radiator looks fresh.

Thanks!!
 

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I would simply top it off with quality antifreeze in the proper 50/50 mix.
 

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Use a "Long Life" coolant. You can buy premixed (with distilled water, so no minerals) in a lot of places. No difference from car to bike. You will not need a gallon. Buy a quart bottle.

And DO not fill to "Max" line.....just to "Min" when cold.
 

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The radiator pressure caps are known to get weak, they can not keep the pressure that normally builds up .

But there is a radiator pressure cap from KTM that holds up 1,8 bars. For models up to year 2016.

125 EXC 08-16
125 SX 07-15
144 SX 07-08
150 SX 09-15
200 EXC 08-16
250 EXC 08-16
250 EXC-F 08-16
250 SX 07-16
250 SX-F 07-15
300 EXC 08-16
350 EXC 12-16
350 SX-F 11-15
400 EXC 09-10
450 EXC 08-16
450 SMR 08-12
450 SMR 13-15
450 SX-F 07-12
450 SX-F 13-15
500 EXC 12-16
505 SX-F 07-08
530 EXC 08-11
 

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I had this same problem mine due to blown fuse so my fan wasn't working.
 
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