Thermostat R&R - K-Bikes.com - Excellence in Motion
 
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post #1 of 4 (permalink) Old Sep 16th, 2010, 10:36 pm Thread Starter
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Location: evergreen, colorado, usa
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Thermostat R&R

Greetings fellow K-bikers,
Would appreciate any info, tips or real life experiences on how to r&r a thermostat for my '02 K1200rs.
Thanks.
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post #2 of 4 (permalink) Old Sep 17th, 2010, 3:37 am
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Why do you think it needs R&R?

Get a Clymer or oem manual

Remove plastics.

Remove right radiator.

Thermostat is in bottom ABS housing.

Remove thermostat and check it is shut.

Stick it in a pan of water and start boiling it.

When the thermostat starts to open, check the temperature with what is stamped on the side.

Check thermostat is fully open when the water is boiling and fully closed when cool (no sticking).

If correct, you went to a lot of trouble for no good reason!



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post #3 of 4 (permalink) Old Sep 18th, 2010, 10:47 am Thread Starter
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tips on r&r 02 thermostat

Thanks for the info. After 40k bike began running hotter than normal ( 1/8 needle below center mark) during usual riding. Checked fans and fuses running normal. It would not overheat (into red) but get alarmingly close. Dealer not very useful about possible problems. Thus, decided to check thermostat. Any other places/items to check?
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post #4 of 4 (permalink) Old Sep 19th, 2010, 4:27 am
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You may have guessed that I wasn't putting the thermostat first.

I'd have thought that 1/8 below center mark was about right. What happens with these bikes is the cooling capacity is extremely marginal. Once the gauge hits half way the thermostat is normally fully open and you are only left with air flow and presssure cap to keep it down. Fans normally come on at about 2/3 gauge. If BOTH your radiators are running evenly hot at the half gauge mark, then your thermostat is fully open and it's a waste of time checking it.

You need to go through a check list to get a few more percent of cooling capacity back:

Remove both rads and flush them through with a hose.

Carefully clean out any muck blocking the fins and straighten any that are buckled or twisted.

Spray the fronts with some black paint if you have a can handy.

Replace the pressure cap so you know you have one that is a good pressure seal.

Replace the coolant with fresh.

NB it is easy to get air locks when refilling (closed thermostat slows filling to right rad.) I now fill with coolant I've boiled first and burp the bottom hoses. Don't fill the left side rad. right to the top of the filler neck first and run the bike at idle for several minutes with the pressure cap off. That also helps to work out any trapped air. Then top off, replace the pressure cap and top off the level in the reservoir.

Gauges can change their accuracy so you should look for other signs of overheating, usually the fans coming on a lot more than you are used to.



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Last edited by voxmagna; Sep 19th, 2010 at 4:39 am.
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