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

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 28 Old 06-28-2013, 04:37 PM Thread Starter
1st Gear
 
Join Date: Jun 2013
Location: US Georgia
Posts: 42
overheating at idle

Finally got my 2003 klr 650 up and running after cleaning, wiring harness connection to front, cleaning the carb, changing fuel lines, charging battery, checking spark plug, changing fuses,and spraying a very tiny amount of starting fluid.

Now it is overheating after about 5 minutes of idling. I refilled the radiator reservoir with water as it had boiled off. I had no problems with the radiator running over a 100 miles the first day I had it so II'm assuming I made a mistake. Any thoughts?
crackbottom louis is offline  
Sponsored Links
Advertisement
 
post #2 of 28 Old 06-28-2013, 05:04 PM
5th Gear
 
Join Date: Jan 2011
Posts: 4,418
BURP your radiator, crackbottom louis!

Radiator cap off, idle the engine 'til the coolant CIRCULATES, allowing air bubbles to be purged. After allowing the coolant to circulate for a few minutes, turn off engine, top off coolant in radiator and in coolant reservoir.

Air pockets can interfere with coolant circulation at idle, when at speed (higher rpm), no problem exists.

DID YOUR FAN COME ON WHILE "OVERHEATING?" DID THE TEMPERATURE GAUGE NEEDLE ADVANCE BEYOND THE RED LINE?
Damocles is offline  
post #3 of 28 Old 06-28-2013, 05:04 PM Thread Starter
1st Gear
 
Join Date: Jun 2013
Location: US Georgia
Posts: 42
Question

Ahhhh! Fan is not cutting on! Guess I have to figure out how to fix that. Advice?
crackbottom louis is offline  
 
post #4 of 28 Old 06-28-2013, 05:34 PM
2nd Gear
 
a4twenty's Avatar
 
Join Date: Apr 2013
Location: Ontario, Canada
Posts: 232
have you checked the fuse?
a4twenty is offline  
post #5 of 28 Old 06-28-2013, 05:40 PM Thread Starter
1st Gear
 
Join Date: Jun 2013
Location: US Georgia
Posts: 42
I have only found 2 spots for a fuse for a total of 3 fuses. Main box by battery and one behind radiator reservoir. Those are good. Is there another I can't see?
crackbottom louis is offline  
post #6 of 28 Old 06-28-2013, 06:37 PM
5th Gear
 
Join Date: Jan 2011
Posts: 4,418
louis, here's your fan wiring diagram from BigCee (to which I preveiously referred you); yet . . . I think you might profit from consultation and counsel with someone local to you with some motorcycle maintenance and repair experience.



Just as an aside, the fan relay and the starting circuit relay are identical parts; you can swap 'em out for diagnostic purposes.

CAVEAT: Generation 1 only.

P.S. Your fan won't come on 'til the thermal switch in the lower portion of your radiator is activated; at a coolant temperature around 200 degrees F.

Last edited by Damocles; 06-28-2013 at 06:40 PM.
Damocles is offline  
post #7 of 28 Old 06-28-2013, 08:40 PM
4th Gear
 
Join Date: Oct 2006
Location: Pefferlaw,Ontario
Posts: 1,636
Just ground the fan switch...take the wire off the thermal switch at the bottom of your rad and touch it to a ground if it's a Gen I bike and see if the fan works...if it does it's the thermal switch which is at fault.
I hope the temps didn't get too high as to have warped the head. Check the oil for coolant contamination and also the coolant for oil contamination. If none you may be very lucky but see if you can do a leak down test and see if either oil or coolant shows signs of air being forced into either one.
You don't need to run the bike to check the fan just turn the key on and ground out the wire against a good known ground, engine, frame......or battery neg as a best option.

Willys
willys is offline  
post #8 of 28 Old 06-28-2013, 08:51 PM
5th Gear
 
Join Date: Jan 2011
Posts: 4,418
Quote:
Originally Posted by willys View Post
Just ground the fan switch...take the wire off the thermal switch at the bottom of your rad and touch it to a ground if it's a Gen I bike and see if the fan works...if it does it's the thermal switch which is at fault.
The FAN RELAY is in series with the fan motor; as well as the FAN FUSE.

Thus, even if the thremal switch lead is grounded, the fan will not operate unless a serviceable fan relay and a conducting fan fuse are installed. If the fan doesn't come on when the thermal switch relay is grounded, that's not a sure sign of a defective thermal switch.

The deficiency could be the result of a blown fan fuse, a defective fan relay, or . . . a defective fan motor or any associated connection.

For the fan to operate, the device must receive power through the FAN RELAY and the FAN FUSE, whether the thermal switch is operable or not.

(A waste of keystrokes, perhaps, but . . . the thermal switch provides a ground to the control solenoid of the fan relay, closing the fan power contacts when activated.)



Besides my own personal, hands-on experience working with cooling fan circuitry, I shall now cite famous authorities bolstering my premise: Mr. Ohm, and Mr. Kirchoff.

Last edited by Damocles; 06-28-2013 at 09:46 PM.
Damocles is offline  
post #9 of 28 Old 06-28-2013, 08:52 PM
4th Gear
 
Join Date: Oct 2006
Location: Pefferlaw,Ontario
Posts: 1,636
Thank you for proving me right!

Willys
willys is offline  
post #10 of 28 Old 06-28-2013, 09:17 PM
5th Gear
 
Join Date: Jan 2011
Posts: 4,418
Quote:
Originally Posted by willys View Post
Thank you for proving me right!
Should never have doubted you, willys!

Last edited by Damocles; 06-28-2013 at 09:45 PM.
Damocles is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Overheating jokerlp 1987 to 2007 Wrenching & Mods 5 05-22-2012 01:12 AM
Overheating feo350 1987 to 2007 Wrenching & Mods 5 07-06-2011 10:33 PM
Overheating? Drake 1987 to 2007 Wrenching & Mods 4 04-19-2011 11:36 PM
Battery overheating question royphotog 1987 to 2007 Wrenching & Mods 7 06-30-2010 03:55 PM
Overheating? Help? gottagetagoat 1987 to 2007 Wrenching & Mods 8 08-29-2008 07:16 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome