FE 400 boils

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W

wiktor

Joined
May 3, 2009
Messages
42
Location
Croatia
I have 03' FE 400, I've bought it in October last year and never had problems with boiling because temperatures weren't high till now. Few weeks ago when we were riding i noticed that i lost half of the cooling liquid in the radiator(i refilled it with 0.5 liter of water). Than after some time again, water sprays like crazy from the pipe below rad cap. I have to mention that it was really hot day and i was riding very aggressive and fast on long uphills but i think it isn't normal that i lost half liter of water.

What do i have to look for? Maybe check the pump? Put "Engine Ice" in it? Maybe it is running too lean? Also, my exhaust pipes and muffler are very beat up and are leaking all around, maybe that could be the cause of higher engine temperature?

Oh yes, few days ago i fried the Electrex stator... my advice, stay away from it...
First it fried my CDI, i had to buy a new one, than it fried itself, now i have to send my original stator to sparks. For the money i spent on electrics i could have rebuilt the engine, after 467 hours without any major service(except 2 timing chains and clutch) I think she deserves new rings :twisted:

Did i mention that Electrex sucks badly?
 
I had overheating problems with my 03 400 for a while, after boiling it once in extreme conditions it would boil much more easily than before. I finally fixed it by getting advise on this site to bleed the coolant system carefully after a boil. On later bikes this can be achieved using the bleed plug on top of the head near the sparkplug. On my 03 there is no bleed plug so you should:-

Top up the coolant and note the level.
Lay the bike on it's side (i actually lifted the front wheel a bit while on it's side to get the bike as low as poss).
After about 30 secs and some squeezing of tubes, lay it on the other side and repeat.
Stand it up and check the coolant level.
If you have been successful you will notice a small drop in level.
 
loz16h said:
I had overheating problems with my 03 400 for a while, after boiling it once in extreme conditions it would boil much more easily than before. I finally fixed it by getting advise on this site to bleed the coolant system carefully after a boil. On later bikes this can be achieved using the bleed plug on top of the head near the sparkplug. On my 03 there is no bleed plug so you should:-

Top up the coolant and note the level.
Lay the bike on it's side (i actually lifted the front wheel a bit while on it's side to get the bike as low as poss).
After about 30 secs and some squeezing of tubes, lay it on the other side and repeat.
Stand it up and check the coolant level.
If you have been successful you will notice a small drop in level.
Click to expand...

There is actually a bleed screw on the front of the head by the exhaust ports. It's a little allen head grub screw. Very hard to see and just as hard to use.
Bleeding is critical.
 
You could be losing coolant due to a faulty / worn out head gasket resulting in over heating as the coolant level drops.

Fill the radiator and leave the radiator cap off. Start the bike and observe the coolant. If you have bubbles streaming up through the radiator you probably need a new head gasket.

If the weather is good try running pure distilled water with no antifreeze. Too much antifreeze in the mix can cause overheating.

From the doc:

Counter hold nipple when installing hose! Nipple that is pushed in will cause cap to
release pressure prematurely which causes unexplained overheating (Viking).


P2010002.sized.jpg


Also don't overfill the radiator to where water/coolant overflows when you install the cap.

A new radiator cap may be in order. I believe a cap with a higher pressure rating is available from KTM hard parts.
 
berger said:
There is actually a bleed screw on the front of the head by the exhaust ports. It's a little allen head grub screw. Very hard to see and just as hard to use.
Bleeding is critical.
Click to expand...

yeah, I found that one and it's a bugger so I threw the bike on it's side in a fit of pique!
 
I will try everything you said, actually i boiled it 2-3 times already so i wouldn't be surprised if my engine suffered.

Thank you for help!
 
be careful with the 1.8bar cap, because if your head gasket is defective, you will not heal the problem, but make another one, i.e. blow your hose (typically where fitted to the water pump) and as a result you will loose water even faster (visibly from outside, you will observe steam from hose). if you have problems to start hot bike and after it finally runs, you observe steam (white) around motor and from exhaust, its defective gasket under the head or the head itself has tear (visible or not). there are deceitful kinds of such tear, one may come to effect after the head gets hot, one closes itself when hot and opens again when cold.
 
Hi,

Check for bubbles with open radiator cap as Husabutt mentioned, if there is no bubbles i would go with radiator cap change.

Had similirar problem, problem was in damaged radiator cap.
Sealing rubber on it was damaged.


Ola Hrvatska!!!

Drago mi je da vidim još nekog iz Hrvatske.
Odakle si?
Javi se na PM.
 

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