Brand new adv990r with a problem - Argh,

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by alongat, Apr 14, 2013.

  1. alongat

    alongat Long timer

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    Brand new 990r (2012) - took it for its first ride and road on highway for about 15 minutes. Got off onto a side road and noticed that the temp gauge spiked up, got a red warning light and all bars of temperature on and flashing (aka: overheat). Pulled over, turned the bike off, etc. it did not feel hot nor could I smell anything burning apart from my new owner positive experience going down the tubes...

    Anyhow, friends helped me raise the front end nice and high, we opened up the radiator bleeder bolt at the top figuring air in the system but that didn't make any difference. The bike was cooled right down but upon start up, the same red light and flashing bars of temp were there. I noticed that despite indicating an overheat, the fan was not at all kicking on. I disconnected the temp sensor on the rad and jumpered the wires and viola: the fan turned but the warning light and all flashing bars have not disappeared. Do I have a faulty temp / fan control sensor? Does anyone know if that one sensor on the right side of the radiator control the fan AND send temperature signal / reading to the dash?

    Yes, I have warranty on the bike but I don't have a dealer that close to me and I want to ride tomorrow. I suppose I can leave my jumper wire in and run the fan the entire time I ride however...

    Anyone else experience this or similar?

    Thanks in advance - apart from this, the bike kicks-ass!
    #1
  2. zeegman

    zeegman Been here awhile

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    Not sure about the dash indicators but

    Couple of easy things to check

    1. Did you lose any coolant from the radiator overflow bottle on right side of radiator? If the radiator has lost some coolant maybe there is not enough left in the radiator to touch the thermo switch which controls the fan - if so fill it up and watch for puking coolant

    and

    2. check the radiator cap and area it seats on in the radiator for dirt and debris - clean it well. If problem persists maybe radiator cap is faulty (lost its seal) which can lead to puking coolant and overheating - if so replace it.

    If problems persist it gets more complicated and could be any one of:

    - faulty thermo switch or thermo-stat (pretty easy to swap out)
    - leaking water pump seal - will see milky sludge in clutch cover when removed or waves in oil filter from coolant. It is more time consuming but not too difficult to swap out.
    - blown head gasket (sure hope not).

    BTW I have had to burp my 950 at least twice after refilling coolant - it just don't seem to get all the air out the first time. Maybe you still have an air bubble - the dealership might not have done a good job on it.

    MZ
    #2
  3. renogeorge

    renogeorge Let's ride!!

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    Sounds like the bike was not really overheated if light is on at startup. Temp gauge sending unit or gauge???
    #3
  4. smoothride

    smoothride Been here awhile

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    You have a dealer in mississuoga and one in whitby. What dealer did you get it from. It is a new bike.
    #4
  5. alongat

    alongat Long timer

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    I got it from Apex. Right, I forgot there's a Ready KTM in Mississauga now - thanks.
    #5
  6. dog'meat

    dog'meat Presidient

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    But the fan do kick off pretty early, like when gauge reaches 10th bar or so ... never got that overheating situation, tho .. But I guess this bike is meant to run pretty hot compared to others I know... Once fan kicks, if you're in town or slow roads where your speed is 50km/h or less , it never goes off... You really have to speed it up and get serious wind to see it turn off ... I have the coolant slightly above minimum mark in reservoir... :deal
    #6
  7. Peanuts

    Peanuts Long timer

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    The temperature gauge has a seperate sensor to the fan.

    Temperature gauge sensor is in the rear head, left side.

    If the temperature gauge is reading high but the fan does not come on and the cooling system is OK then you have a problem with the gauge or sensor.

    To bump the cooling system, have the bike on the centre stand, remove radiator cap, lift bike by the right handlebar until it balances on the rear wheel and left leg of the stand. Bubbles will come out the motor and the radiator. Keep rocking up and dow till the bubbles stop, then top up, try again, top up and go ride.
    #7
  8. dog'meat

    dog'meat Presidient

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    Do you have pics of this ...? Are you actually lifting the bike or just rocking it to the left pivoting on left stand foot..?
    #8
  9. Dualsport Crazy

    Dualsport Crazy Been here awhile

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    I was at the new Ready KTM in Mississauga on Saturday. They are still not yet Orange/LC8 certified since they are just a week old with the KTM line up.

    Hope you can get it resolved ASAP...
    #9
  10. Peanuts

    Peanuts Long timer

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    Rocking it to the left by lifting it on the right.
    #10
  11. el queso

    el queso toda su base

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    I have not had to mess with my cooloing system, but here's a little trick from the HOW:

    #11
  12. alongat

    alongat Long timer

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    I'm off to Apex tomorrow depending on weather, etc. they'll sort me out - they want to make sure that my new bike experience remains positive. The bike definitely didn't overheat though running with no fan in traffic could have ended up a disaster. I jumpered the fan switch and had the fan running full time like guys do who run in slow, tight trails, etc. apart from this little niggle, the bike kicks supreme ass.
    #12
  13. srad600

    srad600 Been here awhile

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    I've used this trick twice now (at the valve checks and at coolant replacement) and it's worked perfectly both times.
    #13
  14. Dualsport Crazy

    Dualsport Crazy Been here awhile

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    Good Luck Alon...

    Let us know what the out come is & am sure they will look after you since they have their rep at stake.

    Cheers,
    Al
    #14
  15. alongat

    alongat Long timer

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    Problem solved - kudos to Colin and the team at Apex Cycle. Turns out there was nothing wrong with the temp sensor or fan switch - it was the gauge cluster defective and misinterpreting the sensor inputs. They swapped it for a new one on the spot and viola! All is correct in my world again.
    #15
  16. bikepsych

    bikepsych Been here awhile

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    Glad to hear they figured it out. Ride on brothah!!!

    BG
    #16
  17. Deviant666

    Deviant666 Been here awhile

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    That's just normal...not similar to the op's case....
    #17
  18. Deviant666

    Deviant666 Been here awhile

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    Defective gauge cluster? Indian involvement with KTM starts to show its teeth?
    #18
  19. Dualsport Crazy

    Dualsport Crazy Been here awhile

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    Alon I'm glad they solved your issue immediately. Now that what you call great service.

    Enjoy the bike. Its an awesome machine & ride safe.

    :clap
    #19
  20. Dualsport Crazy

    Dualsport Crazy Been here awhile

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    Hey Deviant666...

    The cluster is not manufactured at its Indian partners hub (Bajaj). Theyr'e only making the small cc machines. Infact the Indian counterpart has pumped in lot of cash for KTM to come out with new developments & models which has boosted KTM sales enormously worldwide. They have impacted or I would say dinged BMW sales as well.

    Now BMW is following by getting into a joint venture with TVS in India to grab a big share of the pie .

    :freaky
    #20