Thermo-Bob 3 - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 38 Old 10-21-2015, 04:30 PM Thread Starter
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Thermo-Bob 3

Here's a picture of my Thermo Bob Original in the usual place:


It works great and always has. It's perfectly positioned and doesn't shake, rattle, or roll. The problem is that it tends to get in the way when I need to get the valve cover off. Since I'm constantly fiddling with stuff, that's a nuisance.

What I wanted to do was put the new Thermo Bob 2 on, but I wasn't sure it was going to fit underneath the IMS tank. I contacted Watt-man and asked.

Sure enough, it won't. Underneath the IMS 10 tank there is about 3/4" of clearance between the thermostat housing and the tank. Bill told me the Thermo Bob 2 housing is one inch thick.

He suggested that I might try a Thermo Bob 3, which he originally designed for the Ninja 250 and which is used on snow machines and such like that.

He very kindly set me up with this kit:


The only thing special about this kit is that he didn't install the bypass hose fitting and added a 90° and 45° fitting so that I could fine tune the bypass hose placement.

I'm going to try placing the TB3 where the current bypass fitting is...


...and put the bypass fitting where the original Thermo Bob was.

Since this will be regulating the cooler coolant coming out of the bottom of the radiator Bill has installed a 185° thermostat.

The TB3 has a port in it for a coolant temperature sensor. I've ordered the proper sensor from Trail Tech and will install it. It will be interesting to see the comparison of the temperature at the TB3 vs the temperature at the head and the timing of those temperatures. The sensor should be here tomorrow.

Working at the Speed of Tom™, I should be playing with this next week.

Tom

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“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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Last edited by Tom Schmitz; 10-22-2015 at 08:08 PM.
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post #2 of 38 Old 10-21-2015, 04:36 PM
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Wow, excellent timing; I was just about to order two Thermobob 2's for my KLR's and one of them has the IMS tank. Is your bike a Gen1 or 2; mine is a Gen1 with the IMS 6.6.

Thanks,
Dave
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post #3 of 38 Old 10-21-2015, 04:44 PM Thread Starter
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Dave,

Mine is a Gen 2 with the IMS 10.

If you have at least an 1 1/4" clearance between the housing and the tank you should be goo to go with the TB2

Let me see if I can get a picture of the area I'm talking about.

Tom

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“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #4 of 38 Old 10-21-2015, 04:49 PM Thread Starter
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Here's the problem area with the IMS 10:


Tom

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“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.
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post #5 of 38 Old 10-21-2015, 06:01 PM
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Thanks Tom, I'll check it out; better safe than sorry.

Cheers,
Dave
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post #6 of 38 Old 10-22-2015, 08:03 PM Thread Starter
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Cute little jeeter, innit?



(loosely installed, crush washer not shown)

I'll be wiring this in parallel with my oil temperature sensor with a switch to select between the two.

Tom

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“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.

Last edited by Tom Schmitz; 10-22-2015 at 08:06 PM.
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post #7 of 38 Old 10-22-2015, 09:05 PM
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Installing the TB3 into the lower hose, with the 185 'stat is basically what Watt-man does for the Versys 650.
My friend Mike is very pleased with his Versys 650 Thermo-Bob.
Mike may give us a Versys/Kawa. oil sample to compare to KLR's, yet this year.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #8 of 38 Old 10-22-2015, 09:12 PM Thread Starter
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That'll be good info. Tell him to hurry up! Ride more! Faster!

Tom

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“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #9 of 38 Old 10-23-2015, 10:19 AM
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It appears that I have 1 1/2" between the stock t-stat elbow and my tank so fitment of a thermobob 2 on a KLR using the 6.6 gal IMS tank shouldn't pose a problem.

Cheers,
Dave
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post #10 of 38 Old 10-24-2015, 11:10 PM Thread Starter
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I've got it mocked up.

The bypass T is located much lower than where the Thermo Bob original was:


While the Thermo Bob 3 is located where the bypass T was:


Another peek at the Thermo Bob:


I am awaiting delivery of a new pair of hoses. I swear I had an extra pair around here, but danged if I can find them.

Need to work on lighting for the final pictures...

Tom

Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


Sting like a butterfly.

Last edited by Tom Schmitz; 10-24-2015 at 11:20 PM.
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