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After seeing all the cheese camshafts videos , I’m thinking coolant is the least of your problems.

Hi! Thank you for sharing your experience. I have a 2023 ktm 890R. After one year of ownership and 5600 miles on it, I noticed that the coolant level I slightly under the min (I checked it with the bike on the side stand). I have not noticed any leaks on the floor. During summer where I live we get to 100-105F. I have two questions: I) is it possible to lose some coolant as a result of riding in high temperatures? Ii) the coolant that have now is clear (it is the OEM), however, the manual recommend the Motorex M3.0. Do you think I can top it off with Motorex, and therefore mix it with the original one? Thank you!

Sorry, but for some looking for this jet this video is just useless.

KTM released a new thermostat housing for KTM 890 Adventure / R that supersedes previous part. The new number is 63535019200. The old part was 63535019100. Any idea or information if KTM has addressed thickness of flange on thermostat housing? My bike is at my local KTM shop. They are trying to file an out of warranty claim with KTM since I document my coolant leak since day one. Thanks for great video.

Finally, a video which explains it all! Good job. Thinking of laser cutting an aluminium spacer, instead of making a gasket? Or should it be malleable?

Thank you. You saved me hours

Where did you purchase the hose clips ? Thanks

I recently also discovered a few drops of coolant under my 890 duke R (10.000Km) , I just fastened the clamps a bit more and the problem was solved 😃

Awesome job mate, very necessary maintenance for a great bike. Did you do your valve clearances yourself ? Would love to see a video on that .

Where did you find Reigniter Module and other parts.

My 2019 R I Just buy used in November leaks also I Hope the Sales Dealership will repair it. But have u a Update? Still no more leaks?

sir you saved me a lot of time, I have found everything I need in a single video, much appreciated. what about the oil leaks from the cylinder head, you seem to have this problem too, have you just gave up on fixing it because it keeps on returning?

And what type of material do you use to make the gasket?

What diameter does the thermostat have to make the gasket?

Promo_SM

Thanks for sharing - I didn’t know you can schedule an SOS test with Garmin.

I bet you don’t hear from then maybe you should have got a new thermostat with a newer rubber gasket at the same time you got the new housing

Hello. Thank you for this great video. Hope that you can help me. I have a 2021 890 adventure r and it's leaking coolant very slowly, by night and from the same place as yours did. I saw your video and I am afraid to dive into my bike like you did. Are you a mechanic ? How much time it took you to remove all these parts and to put it back? Is it hard? Can't be done without removing the fuel tank? And last, the solution is to replace the water connector or to add a ring inside to tighten the connection ?? Thank you in advance for your reply.

Thanks for this excellent Video

I’ve just got a 790R, I find the engine braking is near non existent, compared to a 990 i also have. It’s taking some getting used to. Thanks for the tips

Jeremy, good video, thanks! FWIW, I had leaks on two coolant hose ends on 2019 790R. The one behind the radiator, on top of the headers, is impossible to see without removing the radiator and it appeared to have leaked since new. I tightened, replaced one clamp on the water pump end and even added a second hose clamp there with no success. No issues w/ the T Stat housing though. If you are going to this much trouble (removing the radiator) chasing leaks get a set of the Samco Silicon hoses and their heavy duty hose clamps. Absolutely worth the money and solved my leaks and a robust upgrade. Note the torque spec on their hose clamps, it is a lot tighter than I would have ever tightened them. Cheers!

Hello Jeremy from KY. You video is perfect. My clamps were loose too. I would like to get the clamps you used. What brand part number are they? Where did you purchase them. I like the idea of the spring for constant tension through the heat cycle.

Hello Jeremy, your video is awesome, any chances you remember the dimensiones of the ring sealing element yo put in the thermostat?

Well, this was VERY helpful!! I'm curious if you have now modified and put on the 63535019200 part? I have a 2019 "S" version and it's been leaking. All the clamps have been tightened but still happening. Seems likely this is the culprit.

Going back to the original KTM chain tension decal. So would you say the 2-5mm. away from bottom of swing-arm is also good simple method for adjusting sag / tension? Thanks. Kam

Hello, technical question. What sealant (some loctiete?) did you use with thermostat housing? What sealant did you use ?

Hello, I live in the north of France and I'm glad I saw your video to fix my fucking leak! Thank you very much for sharing your experience with lots of details and part references. ✌🏼

Use plastic parts in cooling system is not a good thing, it will rot and warp with age

I own a 21 KTM Adventure R and brought it in for its first service to a KTM dealer. After words my bike was leaking? They overfilled my oil and said they could not find the leak. I brought my bike home and started to investigate the leak. I found a coolant line with a loose clamp. Tightened the clamp no more leak. You would think the KTM Dealer mechanic could have found it? Not plus know not to overfill the oil. Very disappointed in the KTM service.

Do you remember _where_ you found the burner assignment for the re-igniter? (e.g. - channel 1->LF, channel 2->LR, ...)... I _think_ you said you had found it at AppliancePartsPros - but I haven't had luck finding it for 5-burner setup... Great video, btw. THANK YOU.

Bikes not only warming itself, but the whole damn planet.

Hi Jeremy, having the exact same issue as we speak. Do you remember what material you used to make the gasket out of to put under the thermostat? Thanks

Thanks Jeremy, I am about to install a 2010 model 5 burner Thermador cooktop for a friend. I just replaced all the burner tubes and serviced the igniters. Without the gas supply connected while I am bench testing it, the igniters click continuously (with a spark between the igniter post and the burner cap) no matter what position the burner valve is in - just open all the way to fully open. I think from your video that the igniter switches off once it senses that the gas has been ignited. On the 2010 model, only the individual igniter is activated by each burner valve. Fingers crossed.

So you never got back to finish this? WTF?

ktm changed the water connection part number 63535019100 =>63535019200. Maybe you don't need to add a thermostat pad anymore

how tightly to tighten the screws of the thermostat housing

Hi Jeremy, Looks like you have one of the few definite videos on how to permanently fix the KTM 790 / 890 Adventure / R coolant leak. Can you tell me of those OETIKER clamps you're using open up to go around hose without having to remove hose? Do you have a detail video or resource on how to take radiator off? Oh. What was actual diameter of hose going to the thermostat housing? You mentioned you thought some of the OETIKER clamps might big too big. Thanks. Kam

Such a great video! So thorough 👌👌

good power ! is this the stock exhaust pipe ? best regards from austria

Hi Jeremy I have the same problem, but instead of adding a gasket I’m going to mill de plastic part, I’m going to remove .015” (.40mm) . Question, how thick was the gasket that you install ? And the leaking stoped?

Hello. Just watched your video, and just want to say, great info! I have a 2021 890 S and I'm having a small coolant leak upon cool down overnight. Apparently it's still an issue. Any specific way to confirm if it's the housing with the thermostat or just a hose, without pulling it all apart? What's the best way to get one of those custom gaskets if needed? Thanks for your info.

Hello, thank for the video. I think i have the same issue... Was your bike smoking sometimes in the morning when you start it ? Was it leaking on the manifolds ? Thank

This guy can't ride for shit. He's using the clutch to change up, totally unnecessary, just back off the throttle and click her up a gear. He's riding it out of the powerband for almost the whole lap, I mean, what's the point. On the plus side, this bike is identical to my old RG500, and very well looked after. Damn I wish I still had the old girl.

Any updates? Incorrect part? Comment from KTM?

This is fantastic. Brilliant

Thank you for doing this video. I was curious myself. You've done the work. Great job!

I am having a similar issue with my KTM 890 Duke R. I was doing some research and came across your video. With regards to the bolt issue, I noticed in the video that the older housing had thicker shims built into the housing. Very similar to the washers you installed. Did you check to see if those were removable and could be swapped over to the new housing?

Cool. Can i smell Long time behind

Working on a KTM is like building a kit car.

Threads are cut with a Tap, so running one down again won't damage them in any way (use a 'Plug' [Bottoming] Tap). You're more likely to damage them with a DIY-grooved Bolt, as there will likely be Burrs along the Groove(s).