Just throwing out some more obvious junk, dang near free check is the radiator cap. If the spring is weak or gasket is worn, it'll blow by. I've only had this be a problem on higher revving motors....

jbt

 

Not glad to hear that your having the same problem...ME TOO! Same questions needing answers...

Last Thur I was gearing up to leave for the little sahara fri morning. I got my carb seals and needle from sudco and was doing some jetting and of course some test runs. Made a hard two mile run and shortly after stopping I heard the spewing of antifreeze and it was shooting out the pin-hole in the reservior cap...[img]i/expressions/face-icon-small-sad.gif[/img] I pulled the thermostat and it was completely open and I watched it cool and close...I checked the weep hole below the impeller and it was clean. Pulled the cover and turned the engine over and the impeller was impelling. (I haven't check the torque on my head bolts yet) I have noticed that a couple times over the last couple months that my reservior would fill slightly but didn't want to invent any problems to solve and the quad wasn't overheating...I ended up just refilling my rad and running the engine until the thermostat opened and coolant was circulating, killed the engine, topped off the radiator, and had a great weekend at the dunes with my kid. Came home and the reserior level when cool was still at the lower line...go figure!!! I may be off base here but I think that not circulating the engine coolant after refilling is trapping too much air and creating a lower boiling point and in turn generating more pressure.

Please post your findings...

Jim

 

make sure your fans are working [img]i/expressions/face-icon-small-smile.gif[/img] Thats what was wrong with my 01

 

i can ride mine all day on the trails-dunes, and until i start loading it hard (torque) the coolant tank stays empty. but little by little it starts to fill back, until it fills all the way up and starts to push out fluid thru the cap[img]i/expressions/face-icon-small-sad.gif[/img] this is my 2nd head gasket but now with the new pami gasket and pliobond will be the last.

 

Well we checked the water pump seals, re torqued the head, I checked the fan, checked all the hose connections, same problem, must be the head gasket[img]i/expressions/face-icon-small-disgusted.gif[/img]