Ok- I recently swapped a used 97 motor into my 96, and there was only 1 big difference which was the water pump has an extra line 5/16" or so ID coming straight up from where all the other hoses branch off of it. This hose goes to the back of #2&3 water jacket I believe, but why? The '96 motor didn't have the fitting into the cases, and the extra outlet on the water pump.

The reason I'm asking, is that I'm 99.9% positive I have everything hooked up correctly because the hoses really won't go anywhere else. I'm having a coking issue, like blockage or something.

Here's what I do know:
I bled the system per manual
Using 50/50 mix coolant with ww additive
The system passes the "overheating pressure test" so no leaks..
The overflow works from the rad to res.
The engine will not cool at speed, but the rad is full of hot coolant?
Thermostat works properly-(tested it)
Fan works
Fan switch works, but doesn't go on when I believe it should-(or rad temp is different than sensor at the head?)
(Fan was working at one point when bike was in the process of overheating)

I know the cooling system worked on the other motor, so I could swap the pump and rad, but the extra lines concern me....

More to follow-
Any advice will be greatly appreciated!!!
Thanks!

 

I found out that the cooling system works just the way honda thinks it should, when you remove a folded, and rolled up paper towel from the return hose.

well, from the radiator, the water pump, the thermostat, the overflow tank, the …. well, you know what I mean….. I think I was a teenager the last time I pulled such a dumb *** stunt like that!

 

You'd be better off asking the 1000F/Hurricane guys.
Come down and visit