Help needed! Cooling system problem...

[tangyeefun]

Ha, yeah man. But I guess it is a combination of many faults.

First Tubing was faulty, changed one of them.

Then found wiring to fan short circuit. Change all wiring system.

Then found other tubes was also faulty, changed all of them

Fan not working well at first, but couldn't realised it becuase they off the headlight everytime they work on my bike

Finally when headlight was on, found not enough voltage going to fan (I think circuit runs parallel to the headlight as well)

Changed the batteries. Fuse blown twice. Changed as well.

Found wire connected to fan melt. Changed the whole circuit.

Then realised that the first radiator cap was not suitable for fazer, changed it.

Then found metal clamp faulty, changed it.

Then when everything was checked, suspected water pump faulty, this time bike left in the bike shop for a week. Did many tests. When I sent in the bike, the petrol tank was full, when I collect it, it was almost empty from all the test ride done around Singapore. Engine oil was change, coolant was change the third time. water pump was changed. Told me if still happen must be the gasket leaking.

When decided to changed the gasket. couldn't find any leakage as no stain near the gasket. Found debris stuck at the radiator cap. Removed the debris.

Lastly suspected cap not suitable. Went to buy original cap. Found gasket really leaking...

 

There is a switch at the handlebar, which I don't know what the hell is. I believe it is the fan bypass switch bought by the previous owner. Bad thing is when the cooling system was faulty, the previous owner didn't do anything to fix it and just bought a bypass switch to use the fan to cool the bike down. Things just get worse and worse. I believe the bypass switch wiring was not fixed well, which causes a lot of short circuit. The good thing is I changed the whole cooling system at super minimal cost. Going other place I would have spent many hundreds of dollar.

 

I'm still waiting for the gasket to be changed and test ride again for another week.

Thank you everyone for your generous advices. Wait for me to confirm that the problem is finally solved if I ride for 3 weeks without any problem.