My 93 with mods listed below always blows about 2 Qts. of water out the overflow every ride. I run it with the t-stat out and with it installed and no difference. Any ideas? It's been doing it ever since I had the engine work done, but I just add water before every ride.

 

I got a stronger radiator cap from my dealer, put a Pro-design Super Cooler on, wired my fan always on, took my voltage regulator off so the fan spins a lot faster at higher revs, and stripped the paint off my head, cylinder, and valve cover. Now I barely lose any fluid. Before it would blow out all of my water after a 5 minute ride. The two things that helped the most are taking off the voltage regulator and stripping off the paint from your motor. The voltage regulator is the little "black box" with fins on top under your headlight plastic. Stripping the paint is the hardest but if you have the time is worth it. It took me about 3 hours plus the time it takes to tear apart your engine and the money for gaskets and paint stripper. The engine also looks MUCH better and I plan to do the clutch and ignition covers soon. Good luck!

P.S. It took me 2 months and hundreds of dollars to fix my overheating problem and I wouldn't run your machine very long while it is overheating or you WILL need to rebuild your top-end(I did).

 

Wow! I was really thinking (hoping) the rad. cap was not working. Do you have similar mods to your Mojave as I do? Is that all that voltage regulator does? I also have a super cooler. How do you wire the fan to "always on"? How much for the new cap? Thanks for the tips.

 

to wire your fan to run all the time, remove the leads from your temperature switch on the radiator and connect them with a butt connector. make sure you use grease on the connection to prevent corrosion.

 

I have a ported head, K&N filter, and Big Gun exhaust for my motor. I have so many aftermarket parts on my chasis that I don't feel like listing them all but it realy doasn't matter. The radiator cap cost $30 from my local dealer. All the voltage regulator doas is prolong the life of your headlight. I have removed my headlight so that is not even a concern for me.

 

Mojaveracer I wired my fan to "always on" and I called a mail order place about the stronger rad. cap and he didn't see a listing. Do you have the part # and are you sure it's a stronger one because I know how some of these dealers like to tell you what you want to hear. I also disconnected my voltage regulator but I could see no visible difference in the fan speed, is that typical? I'm a little leary about disconnecting it because I have a Goki elc. start kit installed and the battery stays charged off of the headlight. Do you think that might affect the starting system? Did you ever consider striping the paint on the radiator itself? And what about those cooling system additives like engine ice? Thanks again.

Also I see you didn't list a higher comp. piston as a engine mod. It's hard to believe that just porting and a pipe would cause this overheating. There goes my theory of blaming it on the 11.5:1 piston I'm running. I think I will give Four Stroke Tech a call to see if he has any added input. (he did my porting)

 

I just talked to Mickey Dunlop at Four Stroke Tech and he was pretty certain it's the Cometic head gasket leaking pressure into the cooling system, therefore heating the coolant up hotter. He said to use the factory head gasket. He also said that while I have the head off I should have a valve job done. He also said that it could be running lean, but I said the spark plug color looks good. But he sounded real certain the head gasket is the cause.