ktm 525 cooling problem

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  • #100295

    Scott Brown
    Member

    I have a ktm 525 exc that has recently got hot a couple of times and have stripped the motor to do a freshen up and have noticed that the exc,s have a thermostat and a radiator bypass hose and the sx,s dont and was wondering if i should take the thermostat out and block the radiator bypass hose on my exc

    #206369

    Mick D
    Member

    I am of the thinking that the SX models are really designed to be on a mX track. 4 laps and back to the pits to cool down before the next race. The EXC is meant for longer slower riding. I am thinking that KTM have all the extra stuff like a thermostat etc. there for a reason. ;)

    #206372

    Hey Scoot
    My 525 gets a little hot under the collar every second ride. We do some pretty sick hills though and it only lasts a minute or so. I’m with Mick and reckon they have a thermostat for a reason. On saying that I had an old Landrover with a 186 Holden motor in it years ago and it did run better without the thermostat. I am talking almost 30 yrs ago and it really has nothing to do with your problem.
    When and how long does it boil for???
    My 07 525 has 15300+kms on the dial.
    Cheers
    Murph

    #206374

    Hey Scoot,
    Best leave your thermostat in but you probably need to check it opens at the right temp and is not sticking or is rooted. As i am talking from a race engine builders experience the problem with removing the thermostat is that when you are just cruising down the road or trail is that the engine runs way too cool where as with the thermostat installed it regulates the temperature of the engine to run in it’s correct operating range. An SX doesn’t have a thermostat as it usually operates at wide open throttle a high percentage of the time so regulating the temperature with a thermostat is not necessary. I have a KTM450EXC and the best investment that i have made with this is to install a factory thermo-fan.
    Hope this helps. ;)

    Cheers,
    Lefty

    #206378

    Good one Lefty
    Believe it or not that is what happened to the old Landrover/186’s thermostat. Rusted closed or part there of. :pinch:
    Have heard of people fitting computer type cooling fans at a way lesser price of KTM’s price.
    I believe the new 012 Katos are standard with a thermo fan.
    Great idea, although it comes at a price, not financially.
    But I think if you want radiator guards the one with the thermo fan is some what compramised.
    Cheers
    Murph

    #206380

    Hi Murph,

    I have Radiator Guards, Bullet Proof Designs of couse, :cheer: and have absolutely no problems. ;)

    Everyone should buy a set! :laugh: :laugh: :laugh:

    Cheers,
    Lefty

    #206382

    Hey Lefty
    Was told that the new Kato’s radiator guards will be compramised on the thermo fan side (I think the RH).
    Do you have a fan fitted to your 525???
    Cheers
    Murph

    #206388

    Murph,
    I have an 08 450 EXC-R. But having said that i would need to look at a 525 of an earlier model to check it out. But i did a few conversions for 07 250 EXC’s and fitted fans to them with no problems. But with a little inovation i am sure it could be done. Especially as the guards are on the front and the fan is on the rear.

    Cheers,
    Lefty

    #206373

    Chris
    Member
    micknmeld wrote:
    I am of the thinking that the SX models are really designed to be on a mX track. 4 laps and back to the pits to cool down before the next race. The EXC is meant for longer slower riding. I am thinking that KTM have all the extra stuff like a thermostat etc. there for a reason. ;)

    on that subject mine boiled for the first time since I did the jetting yesterday, so I may have to look at a fan fitout,

    Lefty do the BPD’s ones cater for a thermo fan, I heard that with the Force onces you need to make some mods.

    I wonder if 2012 ones come with a thermo fan.

    Chris.

    #206408

    drew
    Member

    the thermo switch in my 640 had died between my trading it and getting her back.

    i used a mount on thermo switch from Jaycar/Altronics. they had 60,70? 80 and 90ยบ variants for around $10-15ea from memory. it works as it should.

    so if you go to fit a fan and don’t have the bung to fit the proper KTM style screw in ones.

    you can use the same as i did.

    and a tip for mounting switches and the like. most auto electrical stuff switch the earth/ground, meaning the power to the fan is on as long as the key is on and they turn the ground on and off.

    i sent one up to Micknmeld with a bracket and fan for his BRP….. but can’ta been any good :whistle: :P :laugh:

    #206409
    chris72a wrote:
    micknmeld wrote:
    I am of the thinking that the SX models are really designed to be on a mX track. 4 laps and back to the pits to cool down before the next race. The EXC is meant for longer slower riding. I am thinking that KTM have all the extra stuff like a thermostat etc. there for a reason. ;)

    on that subject mine boiled for the first time since I did the jetting yesterday, so I may have to look at a fan fitout,

    Lefty do the BPD’s ones cater for a thermo fan, I heard that with the Force onces you need to make some mods.

    I wonder if 2012 ones come with a thermo fan.

    Chris.

    Hey Chris,

    Yes BPD does cater for a thermo fan kit.

    Cheers,
    Lefty

    #206426

    pedro
    Member

    geez all that buggering around just buy a wr haha

    #206370

    pete
    Member

    I’ve seen guys run a small bottle in the air box as an overflow tank and they say it works.
    I’m not sure about it.
    I have also heard that adjusting your needle ( not sure up or down ) to suit summer or winter.
    Someone may be able to explain that better.

    PTW

    #206599
    pete the wulf wrote:
    I’ve seen guys run a small bottle in the air box as an overflow tank and they say it works.
    I’m not sure about it.
    I have also heard that adjusting your needle ( not sure up or down ) to suit summer or winter.
    Someone may be able to explain that better.

    PTW

    The overflow bottle is only for recovery of coolant once the engine cools down. It wont stop the engine from overheating. Once the engine overheats and the coolant pressure overcomes the cap pressure, as the coolant expands, it will then be either dumped out the overflow (onto the ground) or into the coolant recovery reservior. When the engine cools a vacuum is created in the cooling system allowing coolant to be drawn back into the engine, provided the coolant is being drawn from the bottom of the recovery reservior and no air enters the system. It is the same system used on cars, trucks etc.

    As an engine builder I would not recommend using a product that increases the boiling point of the coolant above 120deg C.

    Hope this helps.

    Cheers,

    Lefty ;)

    #206612

    Chris
    Member
    Lefty wrote:
    pete the wulf wrote:
    I’ve seen guys run a small bottle in the air box as an overflow tank and they say it works.
    I’m not sure about it.
    I have also heard that adjusting your needle ( not sure up or down ) to suit summer or winter.
    Someone may be able to explain that better.

    PTW

    The overflow bottle is only for recovery of coolant once the engine cools down. It wont stop the engine from overheating. Once the engine overheats and the coolant pressure overcomes the cap pressure, as the coolant expands, it will then be either dumped out the overflow (onto the ground) or into the coolant recovery reservior. When the engine cools a vacuum is created in the cooling system allowing coolant to be drawn back into the engine, provided the coolant is being drawn from the bottom of the recovery reservior and no air enters the system. It is the same system used on cars, trucks etc.

    As an engine builder I would not recommend using a product that increases the boiling point of the coolant above 120deg C.

    Hope this helps.

    Cheers,

    Lefty ;)

    Good explanation Lefty I learnt somethin’ this morning.

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