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KTM 450 coolant hose routing

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This topic contains 11 replies, has 0 voices, and was last updated by  Mick D 15 years, 8 months ago.

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  • July 22, 2009 at 1:18 am #96859

    Toby
    Member

    Have a mate that has just bought a KTM 450 EXC 08. There is a coolant hose that runs very close to the header pipe. His has melted through radiant heat (it was not resting against it). Just wondering if any of you poor suckers that own these orange beasts have had similar probs. I looked at it quickly and it looks like a very dodgey set up as the hose runs very close to the header. Any help appreciated.

    July 22, 2009 at 1:29 am #144861

    Greg
    Member

    Fossil speak with Scott or Mal at Sutto’s they will be able to get the workshop boys to help you for sure

    TB

    July 22, 2009 at 1:32 am #144862

    Bruce Curtis
    Member

    Dodgy KTMs eh? doesn’t actually seem right for these bikes, usually fairly well engineered, anyway a heat wrap would be the go, but I’d still be worried that a line to help cool the engine is getting external heat applied, so I’d be trying to source a hose that aviods the header pipe.

    probably a bit obvious, but is it the right hose as the ones I’ve ridden with haven’t had this issue that I’m aware of?

    bruce

    July 22, 2009 at 1:42 am #144864

    Toby
    Member

    Mr Blue wrote:

    Quote:
    Dodgy KTMs eh? doesn’t actually seem right for these bikes, usually fairly well engineered, anyway a heat wrap would be the go, but I’d still be worried that a line to help cool the engine is getting external heat applied, so I’d be trying to source a hose that aviods the header pipe.

    probably a bit obvious, but is it the right hose as the ones I’ve ridden with haven’t had this issue that I’m aware of?

    bruce

    Yeah I was a bit surprised. It all appears to be standard. I considered the heat wrap thing but the pipe is that close that if you wrapped it the two would then touch. It runs less than 10mm from the header. Considered shortening the hose but this is impossible because of the bend it has to negotiate. When i looked at it i found it hard to comprehend that KTM had designed it like that. I will have to have another look because I have not heard of anyone else having probs, and believe me if they were all like this one we would of heard plenty about it. Maybe the engine has been apart and the routing is wrong??

    July 22, 2009 at 3:16 am #144865

    Scott Tyszkiewicz
    Member

    Picture020.jpg

    Hi Fossil i beleive its this hose (bottom of the thermostat) What happens when the right hand radiator has a hit it pushes the thermostat closer to the header and causes it to melt. best to buy a set of radiator guards/brace for $175 saves you some money in the long run.

    Also that little bottom hose you can only buy with the thermostat $191.70 (dont forget your OBT discount.)
    Cheers
    Scott

    July 22, 2009 at 10:38 am #144872

    Toby
    Member

    TISCO wrote:

    Quote:
    Picture020.jpg

    Hi Fossil i beleive its this hose (bottom of the thermostat) What happens when the right hand radiator has a hit it pushes the thermostat closer to the header and causes it to melt. best to buy a set of radiator guards/brace for $175 saves you some money in the long run.

    Also that little bottom hose you can only buy with the thermostat $191.70 (dont forget your OBT discount.)
    Cheers
    Scott

    Cheers Scott
    He is going to choke when he hears he has to buy the whole show. He does have rad guards, but the radiator must still be bent as his sits much closer than the one pictured.
    Thanks heaps for the advise. I knew something had to be amiss as KTM would never have made it like that.

    Regards
    Toby

    August 3, 2009 at 11:02 pm #144873

    Toby
    Member

    TISCO wrote:

    Quote:
    Picture020.jpg

    Hi Fossil i beleive its this hose (bottom of the thermostat) What happens when the right hand radiator has a hit it pushes the thermostat closer to the header and causes it to melt. best to buy a set of radiator guards/brace for $175 saves you some money in the long run.

    Also that little bottom hose you can only buy with the thermostat $191.70 (dont forget your OBT discount.)
    Cheers
    Scott

    Has got radiator gaurds fitted already, rads are not bent at all (have thoroughly checked all is true and straight).It is about a 7mm gap between the hose and the header pipe. I do not think the header pipe is after market, but am starting to wonder if it is original (has KTM muffler, but is very loud, apparently it has been gutted?? Buying a new hose is not going to fix his prob. it will just do it again. Wish we had a KTM dealer here so we could go and look at a new bike to see what is different.

    August 3, 2009 at 11:51 pm #146839

    Bruce Curtis
    Member

    Maybe header is a mismatch or has taken a hit Fossil?, although that would be fairly obvious.

    sounds like one that got past QA in the factory.

    BC

    August 4, 2009 at 12:00 am #146843

    Toby
    Member

    Mr Blue wrote:

    Quote:
    Maybe header is a mismatch or has taken a hit Fossil?, although that would be fairly obvious.

    sounds like one that got past QA in the factory.

    BC

    Yeah! It has got me stuffed,I feel sorry for the poor bastard as there is no solution to the prob. There is no room to move anything to create a bigger tolerance, and like TB said it will be heating his cooling system also. Shortening the hose will make the hose crimp. I feel it is an issue with his machine because like I said if they were all like this we certainly would of heard about it. His sits much closser to the header than the one in the PIC from Suttos.

    I AM PUTTING OUT A CALL TO ANYONE IN THE HASTINGS AREA WITH AN 08 450 EXC TO PM ME AS I WOULD LOVE TO HAVE A LOOK AT ANOTHER BIKE TO SEE WHAT IS DIFFERENT.

    August 4, 2009 at 1:36 am #146844

    Mick Pilgrim
    Member

    Hi Fossil,
    Bike_003.jpg
    my 08 450 has about an 8mm gap to the header and not appear heat damaged at all. I know a few guys with 08/09’s and I have not heard of a problem.

    Mickp

    August 4, 2009 at 1:40 am #146853

    Mick D
    Member

    The hose configeration on your pic Mickp is different to the pic Tisco posted or am I imagining things?

    August 4, 2009 at 3:30 am #144863

    drew
    Member

    nar your seeing things mich!:P

    you are correct the pic of mickp has the thermo switch fitted. the one scott-tisco posted dose not seem to have it, just a bung/ block off .

    once the hose is replaced, would a heat shield like they flog on ebay lessen the radiant heat transfer?

    could the tune of the bike affect the temp the pipe runs at?

    has the bike with the prob been moded apart from the muffler?

    http://cgi.ebay.com.au/ws/eBayISAPI.dll?ViewItem&item=290336090407&viewitem=&salenotsupported

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