garethpawan

Steve, that is such a clear and useful explanation. Will do exactly as explained and let you know the outcome. Thank you for taking the time to advice a newbie like me. Cheers all for your excellent input - cracking community! Gareth UK

Thanks Steve. Yes the switch is exactly like the one in the photo. Looking at the thin metal retaining clip in the picture, it looks like I may have put it on back to front, with the walls of the clip facing in rather than out towards the terminals of the thermostat. Not sure either, if the retaining clip sits on top or behind the rubber sleeve that goes into the inline housing or where the ties you mention should be attached to put pressure on the clip... Please forgive my stupidity but am a little lost here..

Thanks for your replies. I did wonder if I had put everything back correctly...! Hence my asking about the installation sequence. Can't find anything on the Internet about it but I did it this way: 1. Pushed new rubber sleeve into the aluminium inline housing hole. 2. Inserted thin circlip over the rubber sleeve and around the body of the aluminium housing. 3. Pushed new thermo switch into rubber sleeve and up against the circlip. 4. Reconnected the two spades to the electric wires. 5. Started bike. Not sure if that makes any sense but I tried to replace the thermo switch in the same way I took it out. Might have done something wrong though and am probably being really stupid. However, can't. Find anything on how to do it anywhere.

This is a useful thread to a new member like me. I have a Gas Gas TXT 321. Thought I would be clever and do some preventive work, including replacing the thermo switch for a new one. Why or why did I not leave well alone as the bike was running beautifully. The new switch shot out when the engine warmed up. Okay I thought, maybe there is something wrong with the new thermostat. Solution: Put the old inline one back in, replace coolant and away to go....except it blew this one out too! Where am I going wrong? Anyone know the installation sequence for the thermoswitch as maybe I'm getting that wrong. Could it be air in the system? And would it be disastrous to by pass the switch altogether by hardwiring the two spades together and leave the fan run all the time? Am going to do another trial soon and really need to sort it out...Arrggghhhh!