2008 Fan not working - 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 32 Old 12-27-2018, 11:03 AM Thread Starter
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2008 Fan not working

OK, I am sure this has probably been discussed numerous times but, here it goes;
I just bought this 2008 KLR 650 with 9000 miles for 2500.00. I just had everything ripped off to do some winter cleaning, Doohickey mod, plug change, oil change, radiator fluid change, 22 cent mod and air box mod. When I cranked her up to check out everything, I noted that the fan didnt kick on at all, I dont expect it worked when I bought it.

I assume since I dont know squat about the KLR that this is a Gen.2 and from what I am reading, does not have a fan relay. The temp switch has two wires. I tried grounding out the fan and it does not work (would this work on a Gen. 2 anyway?) I did bypass everything and directly connected to the battery and the fan does work. Since there is not a relay, is the temp switch the issue?

Also, is there a simple thread for adding a manual switch?
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post #2 of 32 Old 12-27-2018, 11:40 AM
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The fan won't come on until the temperature gauge reads almost into the red.

Fire the thing up and let it sit, idling until the temp gauge climbs up towards the red.

The fan will come on.

Do not leave the bike unattended while idling.

You don't need a manual switch. If you do need a manual switch you should fix whatever is making you think you need a manual switch.

If you still think you need a manual switch you can wire one up in parallel with the thermal switch in the bottom of the radiator, but you don't need a manual switch.
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post #3 of 32 Old 12-27-2018, 11:56 AM Thread Starter
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Thanks Tom! I will try and let it get warmer to see if it comes on.
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post #4 of 32 Old 12-27-2018, 03:39 PM
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If the fan motor works with a direct connection to the battery, take a peek at the fuse. Here's the page out of the Service Manual (OEM Model Years 2008-2016) with some other info. 5 and 6 got cut off in the pic, but they're Main Fuse (20A) and Battery.

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post #5 of 32 Old 12-27-2018, 04:56 PM
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Probable blown fan fuse, IMHO.
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post #6 of 32 Old 12-27-2018, 05:59 PM
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The Bottom of the radiator probably was not Hot Enough yet to turn the fan switch on, IMHO.

A Gen 2 temp gauge needs to go higher than a Gen 1 to activate the fan, because of the larger, more efficient radiator.
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post #7 of 32 Old 12-27-2018, 06:03 PM
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[EDIT:]I overlooked Bill10's excellent and comprehensive manual extract above; quite a valid reference.

Even without the manual to guide me, I should have posted:

On a Generation 2 KLR650, SHORTING (or, JUMPING) the thermal switch terminals (ignition key ON) without consequently activating the fan means either:

1. Fan fuse blown.
2. Fan motor wiring (armature, brushes, etc.) kaput.
3. Inadequate/interrupted + 12 VDC wiring or bad ground.

Now, downstream to the thermal switch: Credible test procedure in the service manual; however--fan won't come on even with a good thermal switch if any one or more of the previously mentioned malfunctions exists.

My perception/postulation only.

[See Post # 9 below for a more comprehensive (and more accurate) discussion than this original post contained.]

Last edited by Damocles; 12-27-2018 at 10:49 PM.
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post #8 of 32 Old 12-27-2018, 06:58 PM
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Grounding the thermal switch lead on a Gen 2 won't do anything instructive because it is, well, the switch. One side of the switch sees V+ and the other side sees V+ when the switch activates, sending V+ to the fan motor, otherwise it is just a connection to ground through the fan motor. You can do as the OP did, jump the connector to see if the fan operates; I expect he did that, proving that the fuse was good.

The likelihood that the motor is bad or that the switch is bad, as compared to he didn't get it hot enough to activate the switch, is rather remote.

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post #9 of 32 Old 12-27-2018, 10:10 PM
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Quote:
Originally Posted by Tom Schmitz View Post
Grounding the thermal switch lead on a Gen 2 won't do anything instructive because it is, well, the switch. One side of the switch sees V+ and the other side sees V+ when the switch activates, sending V+ to the fan motor, otherwise it is just a connection to ground through the fan motor. You can do as the OP did, jump the connector to see if the fan operates; I expect he did that, proving that the fuse was good.

The likelihood that the motor is bad or that the switch is bad, as compared to he didn't get it hot enough to activate the switch, is rather remote.
I STAND CORRECTED! The Generation 2 wiring is just as you say. I inadvertently overlooked Bill10's service manual extract he posted above.

I should have said, "With the ignition key ON, SHORT (or, JUMP) the terminals to the fan switch to activate the fan."

I was totally confused by the differences between Generation 1 and Generation 2 fan wiring:

Generation 1: Fan switch + 12 VDC lead hot at all times; fan runs when ignition turned off with sufficient lower radiator coolant temperature closing thermal switch.
Generation 2: Fan switch + 12 VDC lead hot ONLY when ignition switch ON.

Generation 1: Low-amperage control voltage flows through thermal switch, activating fan relay and consequently fan motor when lower radiator coolant temperature closes thermal switch.
Generation 2: Full fan current flows through thermal switch when ignition switch ON and thermal switch closes when lower radiator coolant temperature sufficiently high.

Generation 1: Fan fuse 10 amp; protects fan relay, associated wiring.
Generation 2: Fan fuse 15 amp; protects fan motor, associated wiring.

A thousand pardons for my error!

Still, SOMEONE must disseminate misinformation on this website, no?

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Last edited by Damocles; 12-27-2018 at 10:48 PM.
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post #10 of 32 Old 12-27-2018, 11:06 PM
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Oh, you ain't seen confusion, brother, until you've seen this:


This is a Gen 1 fan circuit built into a Gen 1 radiator (but with a Gen 2 fan!) so that it can be installed, plug 'n play, on a Gen 2 (which itself has Gen 2 circuitry but Gen 1 ignition).

Here's the circuit:


Doing wack crap like this has made me more than familiar with the fan circuit(s).

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


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