2007KLR. 3700 miles
Went for a ride, outside temp was cool enough to keep bike happy on flats, no issues on rd & hwy. Once the KLR was placed under slower pace (less air flow) and workload (climbing). I got a whiff of the radiator fluid and caught the temp gauge at "H"! Stopped immediately! Removed tank, tried grounding-out the “fan switch’ to a solid ground (lower left radiator side), while the power was on, resulted in “NO” fan turning on. Checked the fuse on the right side of KLR (radiator coolant side), 10A fuse bulb not broken. Chased down wires and found no issues (visually). Put her back together, fired her up and let her idle until near a safe hot temp where the fan should have turned ON…again fan did “NOT” turn on. With limited options & knowledge out on the trail and frustration, I returned straight back to the black top, picked up the pace and the cold air kept her cool all the way home.
I know I need to check/troubleshoot and/or replace the following.
1. Thermostat (right side of cylinder head housing)
2. Fan switch (bottom left of radiator)
3. Fan relay (Don’t know exact location, only wire colors)
4. Fan motor
New to the KLR world, great at turning wrenches, not all that great at the electrical. Any links, stickys, videos will help out greatly.
Thanks..young KLR student..
# 3, or # 4, I shouldn't wonder!
Click on this little square below, and you should view a wiring diagram of the fan circuitry:
[Don't know why, but . . . I got a little SQUARE instead of an image.]
Be sure your fan fuse is good, ELECTRICALLY. Appearances can be deceiving.
I rule out # 1; the thermostat's not involved.
# 2? Since the fan does not activate when the lead to the thermal fan switch is grounded effectively, no evidence points to culpability of the fan switch.
# 3? You can jump this relay to test the circuit; also--you have a ride-along backup for substitution; your starter circuit relay is IDENTICAL, if you want to swap 'em for testing.
# 4? Apply + 12 VDC to the appropriate terminal (from the wiring diagram above) to see if this thing then goes 'round.
[If you jump WHITE to BLUE, you'll bypass the fan relay and apply current directly to the fan motor.]
CAVEAT: Generation 1 only analysis and discussion; Generation 2 don't even have no stinkin' fan relay!