Join Date: Feb 2017
Location: Denver, Colorado
Back with some results...
Interesting discussion here...
Having reinstalled the radiator, etc., here's what I've found in summary; it's not overheating as it did the other night, and my fan switch may be suspect. I wouldn't recommend the snake oil.
Fan: I checked the fuse (OK), and then ran power to the white connector (located next to gas tank) that sends power to the the fan motor - the fan worked. I ran a test lead from one of the small connectors on the bottom of the fan switch with the ignition on and the white (power) connection connected and the fan fuse blew. (Perhaps I accidentally touched something wrong...). I figured that the fan blows so rarely that I'll not worry about that for right now and check that again when I get more 15 Amp. micro-fuses.
Cooling system: Reattached everything, filled it up, ran briefly and checked for leaks - none. I went for the same ride that I'd taken the other day to replicate test conditions - the bike ran a little hotter than usual (I've 45 k with this bike), but you could see the cycling of temperature when you started to get a little wind. The temperature gauge read between 1/2 (3.00) and normal the entire time, so I think that's acceptable. I'm taking it camping this weekend, so that'll be it's stress test.
I've enjoyed learning a lot about the KLR cooling system and I think that a stronger radiator will be my long term fix. Even with crash bars, the radiator seems susceptible to damage and the snake oil was a learning experience that I wont repeat.
Thanks so much for the help. Fair skies and good winds, all!