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Old 11-09-2009, 12:19 PM   #1
Albie OP
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Location: Upstate SC
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690 E Radiator leak

Well, looks like the fan sits a little too close to the rad and the blades eventually wore a couple holes into the radiator.
The bikes never been down so I know that didn't happen because of crash damage. The damn fan's just too close. Gonna take it to the dealer later this week and see what they and KTM say about it. A new one costs $500. If they won't replace it for free then I'll just take it down to a rad shop and let them fix it. Then I'll shim the fan housing so it stands of the rad.






Albie screwed with this post 11-17-2009 at 03:48 PM
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Old 11-09-2009, 12:37 PM   #2
BajaDave
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That damage is not actually from the fan blade itself striking the radiator, but rather from the housing itself rubbing/beating/wearing itself against the radiator from vibration and bumps.

I just gave mine a quick feel, and it is not secured tightly enough against the radiator such that it would eliminate movement (it wiggles easily), and that's going to lead to the same problem you have if I don't do something about it. So thanks for the heads up.

There should be some sort of rubber gasket that sandwiches between the housing and radiator that prevents damage and movement and increases fan efficiency. If not, then the whole fan housing should be spaced away enough so that when it jiggles and wiggles and vibrates, it doesn't touch the radiator core.

Warranty should cover it so long as there's no indication of crash to the assembly/radiator/bike. Good luck.
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BajaDave screwed with this post 11-09-2009 at 12:43 PM
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Old 11-09-2009, 12:45 PM   #3
Albie OP
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Ahh, makes sense that it's the housing and not the fan blades. I was wondering why I never heard them rubbing. I really didn't even look at the fan closely after I yanked the rad off.

You're right, some of the other owners may want to take a look to make sure they aren't rubbing holes in them.
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Old 11-09-2009, 02:13 PM   #4
BajaDave
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Okay 690 owners, heads up! Albie's incident has uncovered a design flaw with the cooling fan. I've got 1500 miles on my 690 and just pulled off the fan to check the wear, and it has already started to make slight grooves into the core tubes where the plastic rubs against it. If you don't do something about it, you WILL eventually spring a leak, just as Albie did... it's just a matter of time. It will likely occur after your warranty is up, though, so you should address the problem now.

The problem is that KTM did not use a soft, flexible air seal (like a rubber gasket) to fill what should be an intentionally designed small gap between the radiator and the cooling fan housing. Instead, they designed the fit such that there is no gap (or a very, very thin one), such that the hard thin plastic ring of the fan housing lightly contacts the core of the radiator when fitted. Any movement caused by vibration or shock is translated into friction between the fan housing and radiator core, eventually wearing a hole into it. Bad design... period!

I am going to remove an 1/8 inch or so of the ring on my fan housing and fit a split rubber strip (like what protects the fairing from rubbing into the dash piece on an LC4 Adventure, or like you'd put on the edge of your car door to protect it from chipping paint if you open it onto something) to fill the air gap and then refit it. I'll post pics when I get it done.

WTF KTM?

Check yours!
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Old 11-09-2009, 03:45 PM   #5
rapiti
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That is odd, as the fan kits for RFS bikes came with weatherstripping to fit between fan housing and rad. Quite an oversight. Good luck with warranty claims, guys!


Quote:
Originally Posted by BajaDave
Okay 690 owners, heads up! Albie's incident has uncovered a design flaw with the cooling fan. I've got 1500 miles on my 690 and just pulled off the fan to check the wear, and it has already started to make slight grooves into the core tubes where the plastic rubs against it. If you don't do something about it, you WILL eventually spring a leak, just as Albie did... it's just a matter of time. It will likely occur after your warranty is up, though, so you should address the problem now.

The problem is that KTM did not use a soft, flexible air seal (like a rubber gasket) to fill what should be an intentionally designed small gap between the radiator and the cooling fan housing. Instead, they designed the fit such that there is no gap (or a very, very thin one), such that the hard thin plastic ring of the fan housing lightly contacts the core of the radiator when fitted. Any movement caused by vibration or shock is translated into friction between the fan housing and radiator core, eventually wearing a hole into it. Bad design... period!

I am going to remove an 1/8 inch or so of the ring on my fan housing and fit a split rubber strip (like what protects the fairing from rubbing into the dash piece on an LC4 Adventure, or like you'd put on the edge of your car door to protect it from chipping paint if you open it onto something) to fill the air gap and then refit it. I'll post pics when I get it done.

WTF KTM?

Check yours!
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Old 11-11-2009, 01:30 AM   #6
mattis
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Thanks for the headsup! Remember to post pictures of your solution :)
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Old 11-11-2009, 02:54 AM   #7
Sutherngintelmen
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Solution

+1 on fix - bike has 1800 on it - need to take a look.

Quote:
Originally Posted by mattis
Thanks for the headsup! Remember to post pictures of your solution :)
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