STILL overheating... I'm about to give up on this thing!!

EFI => sensor problem would be my first place to look, need a voltmeter to troubleshoot it.

 

Undo all your hoses and use a garden hose to make sure you have good flow through radiators.
Check that you have water flow through water pump and engine the same way.
You can drain your new coolant into a bucket to reuse.
I do remember seeing the post about hoses being connected wrong, but I can't see how you could do that. They more or less only fit one way.
Fill it up with plain water with everything reconected and run the bike with cap off.
When cold you will see very little movement of water through the filler.
Once it starts to heat up it will swell a bit, but will not start flowing properly until thermostat opens, mine does that at around 80oC.
When it opens, you should see water rushing into the top of radiator suddenly and level will drop.
Keep it running and fan should cut in at about 104oC, and shutt of around 90oC.
After this, at least you'll get a better idea of where the problem may be.

 

This is a very good point!

Some years back the coolant temp gauge on my truck suddenly began to indicat that it was running much hotter then normal. Yet the actual coolant temp tested out to be "normal" when I stuck a thermometer in the radiator. Turned out to be nothing more than a bad ground and/or connection on the temp sensor circuit.

Edit: forgot to mention that I changed the coolant temp sensor before I found the bad ground...

 

Don't confuse the symptoms with the root cause--the symptom is overheating, and 3 shops have checked the coooling system, etc. and found no issues. That's because the root cause is not the radiator.

What makes a bike overheat? Running a lean mixture is one thang. What do the plugs look like, are they white and pale from a hot lean mixture?

What controls the mixture? A damn computer, and it is looking at sensors to tell it where to set the mixture. Primary sensors involve rpm, engine temperature, air temperature, some kind of manifold pressure or airflow, and some kind of throttle position device--5 maybe 6 electronical sensor thangs.

Gitcha a voltmeter and the FSM troubleshooting guide and wrang those bad boys out to find the culprit, or rule them in or out as problems. Obviously the shops couldn't be bothered to do the job correctly, so you will have to DIY.

If it's not throwing a fault code, then it's possible that a sensor has not totally failed but is out of range or tolerance, and is providing false reading (e.g. temperature, most likely). Try disconnecting some temp sensors and see if it throws a code or runs differently, then put it back in, as another way to troubleshoot that mess.

You do have an opened up exhaust so it is going to be running leaner than OEM due to that factor also, but something is throwing you past the margins and over the edge. Good Luck to ya!

 

Had a bad 02 sensor on a car that did not throw a code or exhibit anything when you plugged in your scan tool. It came to me one night though and I fixed it, don't wana strain my arm patting my self on the back either. Was a lean condition that got worse and would result in rough driveability (hot + cold) no over heating though.

Good luck.

 

I've run the Leo's on my 07 for 20k miles, no baffles, no other mods. Never an issue. According to Leo Vince there are no fueling changes required for this application.

+1 to Ridevfr. If there was a lean condition that caused cylinder temps to be high enough that lead to overheating, there would be other symptoms. Drivability issues, possibly lean mis-fires at higher rpm's.

 

Sure it's not binding brakes etc? They can produce uber-heat when binding badly enough!

 

GratefulMonkey any progress or updates?