I finally found and bought the bike for the big trip (KTM Military). Thankfully it doesn't need much prepping, but I want to make sure everything is in order before I set off. I'm about to exchange the coolant, and whilst I am at it, I thought I might as well clean/check the thermostat as well.

I did measure the thermostat and it starts opening at 68.5 deg C (ought to be 70) and is well open at 75 as it should be. So far so good. However, there are a few things I noticed that I thought were odd, and as I am new to all this, I wanted to ask what you think, if the thermostat is still ok.

Firstly, when open, it adopts a bit of a "bent" shape:



Secondly, I noticed a kind of dent along the rim on the top, that leaves a little hole, so the thermostat is never totally closed (12 o'clock position) - should it be that way?:



Lastly, there is something I'm not sure what it is? Dirt? Corrosion? Welding?



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Do you think it's ok to leave from Europe -> Nepal with this or should I better replace it? Thanks!

If the valve doesn't open all the way then I would replace it. If it looks bent (I cant tell properly from the photos) then it may jam one day and your engine will cook and probably sieze.

Even if it only partly opens, you wont get sufficient flow through the cooling system.

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Thanks for the response. It does open as far as it should (>8mm I believe). After cleaning it a little, the odd patches turned out to be solder, so that's fine too, the only thing that still looked strange was this little 'dent' shaped thing (12 o'clock picture 2 above). For now I have put it back in it's place, but I will show the pics (I have some more) to a KTM mech, once I get hold of one. There isn't a single KTM garage near me, so that may take a while

I have a feeling that the first symptoms of over-preparation may be creeping in ...

I was going to suggest this, but you have the internet so why not do with a KTM specialist what you have done on here: send them an image.

You could even send it straight to the factory in Austria, and a few main dealers here and there and see what response you get. Alternatively, there must be plenty of KTM forums, or try Thumpertalk.

The picture is plenty clear enough for them to be able to tell if it is as it should be!!

Throw it away and buy a new one .
Thermostats are cheap , bike engine rebuilds are not .

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