Over heating problem! - 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 13 Old 11-02-2013, 05:08 PM Thread Starter
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Over heating problem!

Hi every one,

This is my 2nd thread on KLR forum; once again i ran to a problem with my 2007 KLR, and I need help.

The bike has 6000 miles on it, and it seems that the cooling fan doesn't work (over-heated a few times idling in traffic; ambient temp. being around 50 degree).
I grounded the thermal switch red & white wire on the bottom of radiator to test the fan, as it was suggested on previous threads regarding this issue, and the fan didn't work.
I'm trying to locate the fuse fan for inspection and to replace in it, but I don't know where it is.

Other than faulty fuse, what else could cause the cooling fan not to operate? Any suggestions? Thanks.
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post #2 of 13 Old 11-02-2013, 06:34 PM Thread Starter
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Can you guys give me any pointers..? I really appreciate.
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post #3 of 13 Old 11-02-2013, 06:40 PM
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Quote:
Originally Posted by worldpeace View Post
I'm trying to locate the fuse fan for inspection and to replace in it, but I don't know where it is.
I am the KING of taking the bike apart to find that fuse. On the gen1, it's inside a white capsule attached to the coolant overflow reservoir frame, right-hand side. Take the panel off the right side of the tank, and you should see it.

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Other than faulty fuse, what else could cause the cooling fan not to operate? Any suggestions? Thanks.
I'll bet it's the fuse. Did you crash recently and bend up the radiator? I hear the fan can get physically jammed and then kill itself. (Let's just hope it's not that because those mofos are surprisingly expensive.) Give it turn with your finger (with the bike off) and make sure it spins freely. There'll be a little bit of natural resistance from the fan motor.

Since it doesn't run when grounded, it's probably not the temp sensor.

But assuming it's the fuse, the question becomes: why did the fuse blow? On mine, it's because the wiring harness rubbed through a bolt that was on the coolant overflow reservoir frame. I put a new fuse in, it was fine for about a mile, and then bzzzpt. Shorted out again, and the fuse blew again. I was on the trail, so I fixed it with duct tape (never leave home without it), and that lasted the rest of the trip until I got home for a proper repair.

Might be worth taking the tank off for a visual inspection of the wiring harness.

Or maybe the fuse just blew because it was old. I don't know how often that happens, but it seems unlikely.
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post #4 of 13 Old 11-02-2013, 06:45 PM
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Besides the likely blown fuse, a faulty FAN RELAY could be the cause of the problem.

Good Generation 1 fan wiring diagram . . . from Clymer, or somewhere else . . . previously posted, if I can find it, I'll put it up again.
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post #5 of 13 Old 11-02-2013, 06:58 PM
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Quote:
Originally Posted by beejjorgensen View Post
I am the KING of taking the bike apart to find that fuse.
Bwaaahaaaa!!! Sounds as though you have personal and in depth experience with that issue!

Gray-haired riders donít get that way from pure luck.

Unknown
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post #6 of 13 Old 11-02-2013, 07:04 PM
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Bwaaahaaaa!!! Sounds as though you have personal and in depth experience with that issue!
Yeah, it was pretty epic. *blush* You guys would have had a field day watching me go to town. "Getting warmer... warmer... no, colder..."
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post #7 of 13 Old 11-02-2013, 07:37 PM
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I feel your pain.....been there too many times !!!

Gray-haired riders donít get that way from pure luck.

Unknown
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post #8 of 13 Old 11-02-2013, 11:03 PM Thread Starter
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I found the fan fuse box/capsule using your description beejjorgensen, replaced the faulty fuse (it didn't look blown!) using a replacement 10A fuse that was already inside that white capsule, tested the fan and it begun to work. Thank you so much guys.

I noticed that fuse box/capsule was zip tied to the coolant overflow reservoir frame. Is this something from the manufactory?

While I was looking for any wire shorted out, I observed that the horn that is also attached to the same coolant reservoir frame is kinda loose. Could that be the cause of shorted out and resulting to fan fuse to blow? I don't know.

My last question is that do you think my engine had suffered or damaged as a result of running on H(hot) for about 1 minute or 2, on two occasions?

Last edited by worldpeace; 11-02-2013 at 11:08 PM.
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post #9 of 13 Old 11-03-2013, 07:55 AM
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[1.] Could that be the cause of shorted out and resulting to fan fuse to blow? I don't know.

[2.] My last question is that do you think my engine had suffered or damaged as a result of running on H(hot) for about 1 minute or 2, on two occasions?
1. No.

2. No.

"Don't worry, be happy!"
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post #10 of 13 Old 11-03-2013, 08:59 AM
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One of the first things I did to my KLR was to replace the glass fuses with ATO blade type. Also moved the rad fan fuse to the front of the coolant cover. There used to be kits available to do this but it's pretty simple to do with parts you can pick up on eBay or .....

Used a rad fan holder similar to this



.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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