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Discussion Starter #1
Noticed this afternoon after work when i started up the bike that it was smoking a bit from the front. Looks like some fluid leaked down on the pipe and the hot pipe was burning it off. It smelled like burnt coolant, if you know that smell.

I smelled and saw this same smoke the other morning when I left as well, but thought it was just exhausting around me since it was a bit foggy and chilly. No issues after at all.

So today i checked when i got home. No leaks. There is evidence of a small leak (really just some dirt and stuff piling up) near the head gasket which I have always known to be pretty normal, but no fluid drips or anything. Bike off and bike running. No issues. Engine temp has been fine.

Anyone experienced this at all?! Explanation? I will try to grab some pics when i have a chance.
 

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High Chic. I had exactly the same problem. Bike smoking when starting her up. Couldn't find a leak until one morning I had a small puddle on garage floor. Looking closer at the bike I found the leak was coming from the thermostat pipe above the radiator. I managed to get a spanner on the jubilee clip and it was fairly loose. I tightened it up and it's been fine since. Hope this helps Chic.
 

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Discussion Starter #4
Awesome guys!! Something to look for when I get home today! Thank you. Will report back when I find the culprit!
 

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Discussion Starter #6
Mine was the hose behind the radiator above the headers. I got to it from the left side of the bike with an open ended wrench. Tightened it up and no issues since.
 

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Have/ had the same exact issue. Noticed that the cooling liquid had gone down significantly as well!

But it only happened to me when it was cold outside or during the rain. When the weather would be good and dry no smoke would appear. Still haven't figured out what it is but will go looks for any of these possibilities as soon as I can!

I found the smell very odd and even went to the dealer with it, but they couldn't identify anything and thought it would have been the rain as well.
In my mind it smelled like plastic was burning and I was afraid some of the cables was having issues and was melting or something odd like that.
 

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Discussion Starter #9
Read above guys. Take a look at the hoses coming and going from the radiator and try to see if any are loose. Tighten as needed.
 

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Same problem on mine, dont just tighten it, get it to the dealer and get the whole god **** thing replaced instead.
I also had 4 separate leaks on the valve housing which i got fixed under warranty as well.

My salesguy said something like he could not understand what KTM was thinking when they put a round clip on an oval pipe.
Although i do not know if he talked about my coolant leak or something completely unrelated to my bike.

We were mainly discussing quality on bikes in general but he knew my bike was in for warranty.
 

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Same problem on mine, dont just tighten it, get it to the dealer and get the whole god **** thing replaced instead.
I also had 4 separate leaks on the valve housing which i got fixed under warranty as well.

My salesguy said something like he could not understand what KTM was thinking when they put a round clip on an oval pipe.
Although i do not know if he talked about my coolant leak or something completely unrelated to my bike.

We were mainly discussing quality on bikes in general but he knew my bike was in for warranty.
Had the hosing and thermo replaced on mine under warranty and it was fine for a few weeks and then started leaking again. Took it to a different dealer and they confirmed that leak was originating from the connector on the hose to the thermostat. He also mentioned that the thermostat connector side was a funny shape although he said teardrop, does seem a bit silly for a round hose. He said they had connected the hose but put the clamp on the narrow edge rather than the rounded edge. They moved the clip and put a bit of sealant and no issues since.

I haven't bothered looking or confirming any of this as it was all covered under warranty, but the leak is gone.
 

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Had the hosing and thermo replaced on mine under warranty and it was fine for a few weeks and then started leaking again. Took it to a different dealer and they confirmed that leak was originating from the connector on the hose to the thermostat. He also mentioned that the thermostat connector side was a funny shape although he said teardrop, does seem a bit silly for a round hose. He said they had connected the hose but put the clamp on the narrow edge rather than the rounded edge. They moved the clip and put a bit of sealant and no issues since.

I haven't bothered looking or confirming any of this as it was all covered under warranty, but the leak is gone.
Nice info thanks, i just came from my salesguy and i confirmed what he talked about with the clip and hose was indeed from my bike, exactly as you described.
Its a crap design basically from KTM from what i gathered.

Seems like i´ll get my bike on Friday, heres hoping for good weather :wink:
 

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Discussion Starter #15
Had the hosing and thermo replaced on mine under warranty and it was fine for a few weeks and then started leaking again. Took it to a different dealer and they confirmed that leak was originating from the connector on the hose to the thermostat. He also mentioned that the thermostat connector side was a funny shape although he said teardrop, does seem a bit silly for a round hose. He said they had connected the hose but put the clamp on the narrow edge rather than the rounded edge. They moved the clip and put a bit of sealant and no issues since.

I haven't bothered looking or confirming any of this as it was all covered under warranty, but the leak is gone.

I seriously hope "warranty fixes" aren't just gerry rigged things I would do on a 20 year old bike. You would think they have a clamp ring that matches the hose. Pretty sad IMO.
 
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