2002 XR650R anti freeze boiling out of overflow hose

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2002 XR650R anti freeze boiling out of overflow hose

Post  john316 on Thu Sep 06, 2012 7:35 pm

2002 XR650R anti freeze boiling out of overflow hose (2hrs of riding in 1st/2nd gears).. Not sure if this is normal or if I should have a mech look at it?

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Re: 2002 XR650R anti freeze boiling out of overflow hose

Post  BuRP on Thu Sep 06, 2012 8:09 pm

Mount a fan, a 4" Spal puller is easy to fit on the rh radiator, to the tabs where the anti-smog stuff was.
The pig will get hot when used at slow speeds as the cooling system was designed for racing, so for high speeds.
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Re: 2002 XR650R anti freeze boiling out of overflow hose

Post  Hew on Thu Sep 06, 2012 9:00 pm

It is also worth checking that the thermostat is working.
It is a common fault with the XR that the thermostat pin gets bent jamming the stat.
Mine was bent near fully open but it was still enough to restrict flow and cause boiling.
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Re: 2002 XR650R anti freeze boiling out of overflow hose

Post  Mauser on Thu Sep 06, 2012 11:51 pm

Take thermostat out listen up

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Re: 2002 XR650R anti freeze boiling out of overflow hose

Post  AURORA on Sat Sep 08, 2012 11:39 pm

john316 wrote:2002 XR650R anti freeze boiling out of overflow hose (2hrs of riding in 1st/2nd gears).. Not sure if this is normal or if I should have a mech look at it?

How much fluid remains in the radiators after the 2 hour ride? affraid

How fast in mph are you running at in 1st and 2nd gear?

Is the thermostat good?
Is the bike jetted properly?


Last edited by AURORA on Mon Sep 10, 2012 6:13 am; edited 1 time in total
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Re: 2002 XR650R anti freeze boiling out of overflow hose

Post  BuRP on Sun Sep 09, 2012 5:34 pm

Mauser wrote:Take thermostat out

As I've said, a very bad idea....
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Re: 2002 XR650R anti freeze boiling out of overflow hose

Post  Focker on Sun Sep 09, 2012 9:17 pm

All found on this site:
Link #1
Link #2

Link - Radiator Fan

Link - SEARCHING TOPICS ON XR650R!!!!! naughty

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Re: 2002 XR650R anti freeze boiling out of overflow hose

Post  AURORA on Mon Sep 10, 2012 6:41 am

·        If you have experienced a boil-over situation with your coolant, consider switching to a radiator cap with a 1.6 or 1.8 rating (stock is 1.1). Honda doesn’t make a 1.8, but a KX8O cap is rated at 1.8 and will fit. The downside to going to a higher rating is it puts more pressure in the system, especially the hoses and fittings.  This increases their susceptibility to punctures and other damage. Remember, this liquid-cooled bike should not sit and idle for long periods without airflow through the radiators. Additionally, the system is designed to boil over and has a coolant catch to handle the escaping fluid.  This does not equal overheating, a common misconception.

·        The Baja race bikes use a 1.8 cap without the overflow tank and thermostat to save weight. They are able to get away with this by careful bike warm-up and racing with the bike wide open. These mods are not for the average rider!
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