Originally Posted by Orangecicle
Chris, your description of having coolant all over your boot seems odd to me. If your overflow hoses are run correctly, the overflow goes from the radiator to the bottom of the overflow tank, and then from the top of the overflow tank out in front of the radiator through the hose that points straight at the ground. I don't see how that could blow coolant on your boot. Maybe I'm wrong.
I've had odd symptoms in the past where I pinched one of the overflow tubes when I put the tanks back on. The result was that the bike would build up pressure in the radiator, then it would build up pressure in the overflow. At some point, typically in the middle of the night, the pressurized system would blow and spew coolant all over the garage floor. Check to make sure that you don't have a pinched line. I kinda think that's not your problem, but it's a quick thing to check.
You mentioned you have sludge at your radiator cap, so think about something like that (clutch cover leak) going on as opposed to a head gasket issue. I thought my problem was head gaskets, and it wasn't. Although we did go ahead and rebuild the top end of my motor, we really fixed the problem just by taking the clutch cover to a machine shop that had a big surfacing table and just surfaced that part. Had I known that, I could have saved $1,500.
All that said, if you find lots of bubbles coming into your radiator on your test, you'll know what your problem is.
Don't worry, you'll get it. Every problem has a solution.
At 65mph, would the coolant coming out of the overflow which is in front of my right foot and higher up, not be able to blow back on to my boot?
Btw, I should note that after the shop had it to diagnose there was no coolant in the radiator at all. I poured in two litres of water and at the breather screw it ran virtually clear right off the bat. And based on that, much of the coolant went into the oil. What had happened to me was the bike ran great at 4 bars on the temp gauge for a few minutes after I flushed coolant and did an oil change. Then in the space of about 1 minute the coolant overflow tank went empty and the temp went from 4 to 8 in that short time, so I shut it off right away to prevent over temp. The shop ran it for an hour according to their report in that condition and I got it back with sludge and 0 coolant. I'm not sure I can now diagnose it as it were or have to start all over again because of what they did? What do you guys think? Rad is currently filled with water and oil is drained but not replaced. I only have enough motorex to fill up, not use for flushing so I would have to buy some cheap Dino oil to clean things out.