Electric help - 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 4 Old 08-20-2013, 02:06 PM Thread Starter
Join Date: May 2012
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Electric help

Hey I had to replace a switch on a 1988 KLR. Someone had jury rigged a toggle switch on it. We replaced the inline fuses. Now when we turn the key on the white wire to the fan relay gets hot and the fan wants to run all the time. Any help?
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post #2 of 4 Old 08-20-2013, 03:48 PM
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what was the switch you replaced for??

on newer models some install a fan switch bypass, to manually control engine temps.........

2013 KLR650
1994 YZ250
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post #3 of 4 Old 08-20-2013, 08:42 PM
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This ain't my first rodeo, regarding electrical issue discussion!

LESSON LEARNED: Accurate and precise IDENTIFICATION of the components under discussion is necessary for meaningful dialog.

So, WHAT switch was replaced? What did the switch control? What circuit was involved? What significance/relevance resides in the fuses?

These questions might be answered by REFERENCE to the Generation 1 KLR650 wiring diagram on the web.

I'll try to post a URL to the wiring diagram by editing this post.

Here you go:


The WHITE wire to the fan relay is constant + 12 VDC.

If the fan runs when the ignition key is turned on, looks like somehow the fan relay is picking up a ground when the ignition switch is turned on.

IMHO, a manual fan switch remains an elegant solution to a non-existent problem: The automatic THERMAL SWITCH installed in the lower radiator AUTOMATICALLY turns on the fan, when coolant temperature reaches its threshold level. BTW, I have a manual fan switch. Fun to play with, I guess, should I wish to delude myself that I control coolant temperature, when actually the stock cooling system stabilizes engine operating temperature within safe limits.

CAVEAT: Comments apply to Generation 1 only; Generation 2 fan circuit varies markedly from its predecessor.

Last edited by Damocles; 08-20-2013 at 08:58 PM.
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post #4 of 4 Old 08-20-2013, 09:51 PM
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What happens when you turn the switch of and on? What does it controll?

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