Hi again,
             I have fitted new seals to the pump using motoworks prototype tool (more on that later!). I refitted the pump using 3 bond and refilled the rad with coolant (slowly and squeezing pipes to help remove air). Filled the the reservoir to max. Now the temp gauge is very jumpy and the fan kicks in just after the blue marks which is a lot earlier the it use to?. I have run the bike at idle it and from cold it takes about 15mins then the fan kicks in (as above on the gauge). I don`t appear to have any leeks (left over night) I have pressure in the rad pipes. Has anyone had this? could it be a sticky thermostat? (it did sit about 2 weeks with any fluids in it) could the gauge be faulty? or do I still have air in the system?
I ran the bike without the rad cap on and as the coolant rose I put the cap back on, Their was a slight change in the level on the reservoir? 
Any suggestions? thanks in advance K.

Update, I think the temp sensor is dead! the temp gauge really started to play up then then was unresponsive. I earthed the gauge and it responded (going to max hot position). K.

dakelvinator wrote:I don`t appear to have any leeks (left over night)

Nor do I. We ate them all.

How did you drain the system to start with?

I would suspect that you have an airlock, release pressure and run the engine without the cap until it warms up. Watch out for the spray as the coolant goes everywhere.

92KK 84WW Olaf wrote:How did you drain the system to start with?

Hi Olaf 
         I just undid the hose pipe so I wonder if when I was cleaning the pump and fitting the seals i damaged the sensor? or may be it had just run its course? do you know if this sensor on the pump only controls the gauge or does it act as a fan switch? (I know there`s a temp sensor on the block just under the rad is this the fan switch?). K.

As Stumpy says. They can get airlocked at the bottom of the radiator if you fill it quickly. Fill slowly and squeeze both the filler pipe and the big fat pipe on the left side. Yuo'd be surprised how much air that drives out.

The pump sensor drives the temperature gauge - nothing else. The temperature sensor under the radiator drives the fan and tells the ECU when to not allow the bike to start.

Dai wrote:As Stumpy says. They can get airlocked at the bottom of the radiator if you fill it quickly. Fill slowly and squeeze both the filler pipe and the big fat pipe on the left side. Yuo'd be surprised how much air that drives out.

The pump sensor drives the temperature gauge - nothing else. The temperature sensor under the radiator drives the fan and tells the ECU when to not allow the bike to start.

Thanks for confirming about the sensor Dai, I have ordered a new sensor so I will drain the system to fit that and try again, I wont need to use the bike anyway so I don`t need to risk causing any damage just in case their is an air lock. Hopefully it will stay "leak/leek" free . K.

Got new temp sensor all good so far!  (just on idle need to give it a good drive), the one I removed from my pump had a blue collar this must have been off a k100? the new one has a black collar. whats interesting is my temp gauge would be on the second bar when the fan kicked in and now the fan kicks in on just before the half way mark. Am I right in thinking the the blue collar sensor and the black collar sensor have different temperature ranges? hence why their is one for the k100 and a different one for the k1100.  K.