If anyone could help me with this problem/nightmare from hell I would be really grateful. Sorry for the long one below, but best to get the facts out, and you can make your mind up.
I think I have found a faulty thermostat on one of our vehicles (not my bike but my partners car) - a '99 Punto motor (60k miles down and head gasket done 20k ago). I think a major fault may be the thermostat (already replaced once before at head gasket failure time) is faulty on this basis of information: I immersed it in boiling hot water, and no apparent movement/opening at all. However it appears to be "failed shut" and not open, if that makes sense!!! I reckon its deffo faulty.
It might explain the overheating aspect (which might POTENTIALLY have warped the head / damaged the gasket I guess)
The problem identified itself at first when we drove for 40 miles to our destination, but the overheating light didnt come on until JUST as we arrived. So any chances of damage seemed to be small as we just stopped immediately!!
We also watching keenly on our return journey the same distance back ( hoping to shrug it off and noting the water hadn't appeared to need topping up at our previous destination). It did come on but quicker, probably 20-25 miles. I had no option (learnt she forgot to renew breakdown -grr!) but to sit and wait until the meter had cooled. So we probably had no more than perhaps 15 miles left, so nothing left but to risk the journey back. It got back, without any apparent event, and no warning light again.
I drained it tonight and the water looked pretty awful looking, like rust and the pipes were pretty mucky inside. Surprising as it was flushed 20k ago (but not reverse flushed through the rad). Oil is really quite ok looking really. A little dark which is usual, it might be a bit runny but no signs of mayo. I have yet to get the rocker off - this may tell more with more signs of the dreader mayo with cheese!!! How much fun is it to clear that stuff up. Not. If its anything like the mayo I saw 20k miles ago, I guess its bad news and time to knuckle it down again with the full Gasket kit and skim.
NO real signs of steam out the back when its running and NO real water leaking on the outside. Where is the water going to ???? What a magic trick.
In retrospect, the girlfriend had been complaining about it being a "bit louder" for a few weeks ( maybe this was a sign, or just misleading ). It very recently had the front lower pipe done recently which also may be misleading for the extra noise aspects, although it doesnt sound like its blowing from there, I still think it could be the head. My father thinks that nipping up the head bolts might help, because of the recent head (well not that recent, about 2 yrs ago but only 20k miles).
Im not so sure, complete head gasket might be the way but I spose I can try this trick first. The only thing to watch is overtighterning, so I can be conservative with my torque gauge. I am looking if necessary at the complete head gasket replacement, new thermostat, checks on fan, water pump working, etc. I done it once, so whats a little more practise. Its just that the weather sucks.
Doesn't seem to be smoking or anything that bad yet - not quite the end yet ? Reckon the little troublesome Italian still has some room left to haunt me. Am I just unlucky given I replaced the 'stat not long ago ! I also had a damn NEW water pump leaking on me the first replacement 20k ago too. I had the partner shouting I had done it wrong. I had great satisfaction in pointing out to her it was the part that time around, not my labour.
Thanks guys
Antony F