Coolong fan check - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 12 Old 04-28-2011, 01:22 PM Thread Starter
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Coolong fan check

I am not 100% sure the cooling fan on my 95 KLR is working. Although the weather has been mild the fan has not come on once in the week I have been riding it. I do not have a shop or repair manual but want to test the fan circuit to ensure it is working properly. Any help would be appreciated.

Here in the Central Ca Valley summer comes fast and 100 degree temps are not too far away, I'd like to be sure my bike is prepared for the heat.

Mark

http://klr-650.blogspot.com/

Keep Me, Protect Me, Share Me - And I Will Live Forever.
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post #2 of 12 Old 04-28-2011, 01:38 PM
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Quote:
Originally Posted by sportster65 View Post
I am not 100% sure the cooling fan on my 95 KLR is working. Although the weather has been mild the fan has not come on once in the week I have been riding it. I do not have a shop or repair manual but want to test the fan circuit to ensure it is working properly. Any help would be appreciated.

Here in the Central Ca Valley summer comes fast and 100 degree temps are not too far away, I'd like to be sure my bike is prepared for the heat.
A functional check of the fan (on your model KLR650) isn't difficult; just ground the lead to the fan switch (thermal switch installed in lower right of radiator, I think).

Grounding this lead energizes the fan relay, and in turn, the fan, on a properly-functioning bike.

Doesn't work? Fan relay, fan motor, and associated connections may be suspect.

Fan STILL doesn't come on, even when the coolant temperatue needle moves into the RED zone?

Could be the fan switch itself; Service Manual tells how to fling the fan switch into hot liquid and measure conductivity . . . switch closes with heat.

Further suggestion: Google, "KLR650 Wiring Diagram" and you'll see how the fan, fan relay, and fan thermal switch are interconnected.

DIFFERENT, pre- and post-2008 models.
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post #3 of 12 Old 04-28-2011, 01:39 PM
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Unplug your sensor wire (be gentle) and ground it to one of the mounting bolts. The fan should start when the wire is grounded. This can be completed without removing the fuel tank.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #4 of 12 Old 04-28-2011, 01:44 PM
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Unplug your sensor wire (be gentle) and ground it to one of the mounting bolts. The fan should start when the wire is grounded. This can be completed without removing the fuel tank.
Picking a nit, TC, I think the wire you refer to is the fan relay actuation wire, in contrast to a sensor wire--the sensor wire is connected between the temperature sensor in the cylinder head and the tempeature gauge.

The wire-in-question connects the fan relay to the fan switch; the latter an ON-OFF, CONNECTED-OPEN thermally-triggered gizmo.

Again, I pick a nit; no offense intended!
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post #5 of 12 Old 04-28-2011, 01:54 PM
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OK...

Pull the wire off the sensor in the bottom of the radiator and press it against a mounting bolt. If the fan starts it is good. If the fan does not start, check the fuse.

Use dielectric grease on this connection when reconnecting.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015
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post #6 of 12 Old 04-28-2011, 02:59 PM
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The fan relay lead (RED/WHITE) connects to Ref: 27010, Part # 27010-1167, SWITCH,FAN, as shown at http://www.kawasaki.com, owner info, parts diagrams.

This pre-'08 wiring diagram may help check out the fan circuit:

http://pdfresh.com/wp-content/upload...-motocross.jpg

I installed a manual fan switch on my KLR250, splicing into the fan relay wire and connecting the switch between the relay and ground. The fan switch in the radiator still works automatically, but I can "over-ride" the fan switch by throwing he manual switch to turn the fan on at any time, regardless whether the ignition switch is ON or OFF. (True confession: An un-necessary modification, with a functioning fan switch!)

But, it's cool, I guess, to be able to anticipate the fan switch. Then, SHOULD the fan switch fail to close under high temperature, I have a "back-up."

/The "base" Service Manual (KLR600) says the fan switch closes on the way up between 201-212 degrees F.; opens on the way down when the coolant temperature is lower than 196 degrees F.

Last edited by Damocles; 04-28-2011 at 03:20 PM.
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post #7 of 12 Old 04-28-2011, 08:59 PM
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Couldnt you just let it idle until it gets hot enough for the fan to come on? That would eliminate the need to dissassemble anything and test the whole circuit at the same time. Just be sure to keep an eye on the temp gauge in case the fan is not working so you do not let the motor overheat.
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post #8 of 12 Old 04-28-2011, 09:51 PM
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^^^^ Thats how I do it. Just let her idle for a while.

Bill
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post #9 of 12 Old 04-29-2011, 02:46 AM Thread Starter
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Wow - thanks for all the advice, I did unplug the sensor wire and when touched against mounting bolt fan came on. Perhaps it was not getting hot enough to come on? I'll be riding all day tomorrow and it should get warm enough to come on if operating properly, tomorrow high 70's - low 80's.

I had considered installing a switch for the fan on my other KLR, I think I'll do it for this bike. I am getting the ABS dash, there is a switch on it I can use for the fan.

Mark

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post #10 of 12 Old 04-29-2011, 09:30 AM
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Quote:
Originally Posted by sportster65 View Post
Wow - thanks for all the advice, I did unplug the sensor wire and when touched against mounting bolt fan came on. Perhaps it was not getting hot enough to come on? I'll be riding all day tomorrow and it should get warm enough to come on if operating properly, tomorrow high 70's - low 80's.

I had considered installing a switch for the fan on my other KLR, I think I'll do it for this bike. I am getting the ABS dash, there is a switch on it I can use for the fan.
Doing the switch mod has been a good thing on my KLR.

When I leave the street and head up a trail I turn it on and leave it. When riding off road you do not run as fast to keep air moving threw the rad.
Works good in stop and go traffic too.

What is nice about it is the bike will still bring on the fan by itself when needed. That and if the sencor should quit working you still have away of cooling the motor.

Kurt

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If you don't mind, then it don't matter!

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