Finally solved the overheating problems!

Shocking.

I was considering a fan to combat this potential issue but may not bother now. A mate and I both ride 2012 FE570s. We'd both easily weigh over 120kg with gear and haven't managed to overheat the bike or boil the fuel as yet. A couple of weekends back we blasted up some long steep hills and soft sand in tropical 35deg C heat with nearly empty tanks (apparently the fuel will boil easier when there's less of it) without boiling fuel. Maybe that this not an issue on the later bikes or larger motors - cant see why they'd be any less susceptible though.

53,
whatever floats your boat! Was there not an easier way of doing this though? Had you not considered insulating the exhaust?? Sorry if you've already been down that route (I've not been following your thread). I'm sure your solution works, but it is wonderfully ugly and I'd be afraid of riding hard in rocky areas. A flattened pipe would slow you down a bit. Been there, done that, wouldn't recommend it to anyone... and that was on a KTM450 with a conventional downpipe!
Cheers... P

I had fuel boiling issues, went to a full on investigation and fix for it. So far, results have been good.
First of all, I had to figure out were all the heat was coming from. Yes, it is the exhaust pipe, but the pipe heats up the frame which also heats the tank.

First, a high quality pipe-wrap was used to reduce the heat from the pipe under the tank. This helped but didn't eliminate the problem. Second was a high-tech heat shield under the lower tank portion. I purchased a piece of Aerogel insulation from ebay. This stuff has a very high insulation value, very high-tech stuff but kinda of nasty (really dusty) to work with. I cut a piece to fit and glued it in place. Next layer was a aluminum heat shield which I fabricated from a aluminum roasting sheet I bought from the dollar store. All edges which sealed with high quality duck tape. I tried the foil type heat tape, but it didn't stick very long. It was a little tricky to get it all to fit since clearances under the tank are tight.

Next was the upper portion of that tank. The bike had the foil convered fabric insulation under the tank when I bought it, which didn't do much. Ripped that out (it was falling off anyway), glued a thin layer of craft foam on the tank, cut the fabric to fit, and sealed again with the good duct tape.

Results are promising.

Over here in the UK I'm finding the 570 massively over cooled to the point where I have to partially blank off the rads for road work to get the temp past 60 degC. This is with ambient temps around 10-15 degC. Even with the rads partially covered it rarely gets past 90 deg on the slow trails. The stat is OK and was the first thing I checked. I wrapped the exhaust, used heat reflective blanket on the tank and fitted the fan kit from new in anticipation of some cooling problems but I could probably have passed on the fan at least. Can't remember the last time it came on during a ride.

Errrr.....what? :roll:

I haven't boiled my fuel yet, 5300 miles so far? Yes, lots of off road, climbs, single track, and hot days. i suspect there was something wrong with the mixture on your bike to run that pipe so hot. Did you ever have the computer program checked to see if it was programmed correctly? BTW, I have seen a much more sanitary looking setup like this. The pipe was routed over the clutch on the case and then split into two smaller pipes and fed through the frame right above the foot rest and connected back into the can at the stock location. Nothing was hanging out, and nothing was where it could get flattened by rocks. It looked very professional too.

I noticed that you no longer have a rear brake or master cylendar. This must add a little to the excitement of the ride.

jonbrogers said:

I noticed that you no longer have a rear brake or master cylendar. This must add a little to the excitement of the ride.

Click to expand...

I just look at those pictures and think this guy must be a farmer because his bike looks like it is being fixed by the tractor mechanic. Personally, I don't see this bike lasting very long, Husabergs and bailing wire don't go together very well. I'd bet he's got some duct tape, JB Weld and a multi tool laying around in the shop too.

Rode my 12 570 in some pretty warm conditions last Saturday, no fuel boiling so far not saying it will never happen but hasn't been a problem so far.

2010 fe 570,,, akrapovic -wrapped, cv4 tank insulator,,,fan,,, -- can't ride in the midwest with all the humidity without the fuel boiling,,


down in the southwest united states, fan rarely comes on (rarely=once every 2/3 hours in the southwest at 90 degrees f,,,compared to 75/80 degrees of humidity in the midwest and fan runs allot), but the heat from the wrapped exhaust heats the frame, and the frame turns the plastic a different shade of grey and then boils the fuel,, so far even with the fuel bubbling, it still works good

would like to learn more and prevent problems

Anyone look at diverting the fan air to the midpipe and tank area to help with fuel boil? The fan air would be ~210F or less, and the header pipe at the tank must be 3-400F.

I regularly ride in hot conditions and have never had my fuel boil. I have read of many people on here having this problem so i take it that it does occur. I have just fitted a fan to my rad but only as a safe guard, South Australian summers are quite warm! That does seem to be a of overkill, especially giving up the rear brake! Ugly too but hey, dirt bikes aren't meant to be pretty. Lucky for you, ha ha!

I have a 2011 570 and the last two years I ran a fan kit with the stock radiators. Only had a problem once with the fuel in stop and go traffic.

This week I made the following changes and now my fuel seems sure to boil after 15 miles. Having bowed both my stock radiators I thought I would upgrade to Fluidyne radiators and try to run without the fan. I also added a CV-4 blanket, CV-4 silicone hose kit, Akropovic slip-on, E-line skid plate and a Golan mini fuel filter. I am going to remove the E-line for the ride home from work but I am dubious it will help much. I am going to drop my stock radiators of for repair if I cannot fit the fan to the Fluidynes tonight. Do not buy the Fluidyne radiators for a 70 degree. They are listed on KTM-parts.com as working with the 70 degree but with the extra width they actually contact the valve cover on the left side. I have a Voyager water temp sensor and the Fluidynes will take the temp to 135F in 50F ambient at 50 mph but at idle the temp will shoot to 240 and possibly higher.

I will post if the E-line removal helps at all. Google them if you have not seen this skid plate. It may be blocking/trapping too much air.

Road a little at lunch and the bike is good cold but quickly goes to too lean with or without the eLine skid plate on. Not sure it is the heat now. Afterburn backfires, surging, stalling. Could this be symptoms of a plugged injector? I think if this were a fuel pump problem it would stop altogether.

The problem is not overheating. Bike is going lean for some other reason. Adding fuel to the tank does not change the issue when it is happening.