Ok, so it's now clear that my bike is boiling over ALL the time. Today it boiled over even after 15-20 mins of riding at speed (between 30-105km/h). No stop and go, slow first or second gear technical riding and I wasn't riding the clutch...
Two-three weeks ago, I assumed I had a faulty radiator cap because the bike was overheating a lot and coolant wasn't being sucked back in (or it was, but took like 40 mins). The bike used to only boil over in technical stuff when I was riding the clutch, and after waiting 5-10 mins the coolant would get sucked back in. That's why I assumed the radiator cap was busted. After looking at other rad caps and comparing them to mine (with rubber "lips" overextending vs ones that are flush), I was sure this was the culprit.
However, that still doesn't explain why the bike would boil over under such riding circumstances. Plenty of guys ride in the desert and from I can tell, this isn't normal. So anyways, today I pulled the coolant lines and lo and behold, there was a leak. So I then assumed the air leak is what made the bike heat up so quickly and prevented the coolant from coming back. It would certainly prevent coolant from going back, but would it affect how fast the bike boils over? ANYWAYS, right after changing the lines I went riding for another 40km and even with the new lines, the bike boiled over after 15km of quick-paced riding (50-80km/h). What the hell?
What should be my next move? So far this is what I'm thinking:
1-Head gasket? I changed my head gasket around 2 months ago after a big failure (blown near the pipe header). Perhaps I messed it up and the new one isn't seated properly? No obvious signs of a faulty gasket or leak, but could this be the culprit of the overheating? I think this is my main target at the moment...
2-Jetting? Maybe a clogged jet or bike is too lean? To be honest, I have NO idea what my jets are. I'm at sea level with ~40C ambient temperature (105F). However, the bike runs beautifully both at idle and full throttle so I don't want to fix something that isn't broken. All I need is a bit of choke when cold and then perfect idling, and strong power throughout.
3- I recently changed my ignition coil because the bike wouldn't start (started by cleaning the starter, but still had problems. Now it starts fine). I think it's from a 250F. Would that affect anything? However, the constant boiling over started being a problem BEFORE I changed the ignition coil, so I doubt that's the cause. I'm just putting it out there.
4-I changed the waterpump bearing and gasket recently. No signs of a new leak. I'll check the oil, but I don't think it's an issue anymore. Impeller maybe isn't working properly? Take off the hose from the waterpump and check if it's circulating?
Other leads? Busted rads? No leaks that I can see... Timing chain? I'm really at a loss and this is starting to frustrate me and making me loose faith in the bike. I've heard on some Aussie forums about putting heat tape on the rad near the header to reduce boiling over. Still, there must be some deeper issue here, as I'm boiling over no matter how I ride. Not normal (or is it?).
Edited by Bitteeinbit, May 11, 2016 - 11:28 PM.