Barr's Leaks -- Overheating! (please help!) - Page 2 - 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 #11 of 28 Old 08-15-2019, 03:32 PM
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terry_g,
Standard OEM thermostat in all KLR's is 160F. Nothing else available in oem diameter, until the Thermo-Bob 2 was available. And it is NOT advised to install the TB 2 195F thermostat into a non by-pass system.

pdwestman
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post #12 of 28 Old 08-15-2019, 05:07 PM
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Quote:
Originally Posted by terry_g View Post
There is a small hole in the thermostat that allows air to vent and a small amount of coolant to circulate when the thermostat is closed.
This small amount of flow causes the engine to run too cool. The bleed hole in the thermostat could have been blocked by the Barrs Leak.
That would stop any flow through the cooling system until the thermostat got hot enough to open which is probably somewhere around 180 to 190 degrees.
If you flushed the cooling system and water can be pushed through the bleed hole should be clear.
I would make sure that the rad is not blocked and then put it together again and see what happens.
Also check Amazon.ca for a replacement rad.

Terry
Appreciate the considered comment, terry_g!

Just a small detail; I believe the stock thermostat opening temperature is 160 degrees, not 180--190 degrees . . . corrections welcomed!

Would a blocked weep hole (even as a function of Barr's Leaks) cause overheating, if the thermostat opens at 160 degrees? Don't know; just askin'!

“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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post #13 of 28 Old 08-15-2019, 05:23 PM
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Quote:
Originally Posted by pdwestman View Post
terry_g,
Standard OEM thermostat in all KLR's is 160F. Nothing else available in oem diameter, until the Thermo-Bob 2 was available. And it is NOT advised to install the TB 2 195F thermostat into a non by-pass system.
NormK sold me a higher-temperature thermostat he obtained from China, as a replacement for an OEM KLR650 thermostat.

In the, "bad old days," folks used to substitute higher- and lower-temperature thermostats in their automobiles, depending upon the seasonal ambient temperatures expected. Reckon one might use one of these as their, "winter" thermostat.

Haven't ever installed this goodie myself; anyone want to experiment with it?

Don't know if the part is available commercially; even if so, the excessive tariff on this Chinese product might make it economically untenable! Regardless, anyone interested seriously in experimenting with this gadget might talk me out of it!

Stand by; I'll try posting an image of the component.

“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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post #14 of 28 Old 08-15-2019, 05:38 PM
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I was just guessing at the temp. When I installed the Thermo-Bob kit in my 2017 I could not see a temperature marked on the factory thermostat anywhere.
The bleed hole in the factory thermostat is way bigger than the bleed hole in the Thermo-Bob thermostat. The bleed hole can let enough coolant pass through to over cool the engine when running under light load.
I strongly recommend the Thermo-Bob kit. Over the long term engine life should be greatly increased.

Terry

Last edited by terry_g; 08-15-2019 at 05:42 PM.
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post #15 of 28 Old 08-15-2019, 05:41 PM
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Stamping appears to be:

SKIII-140402





High-temperature thermostat, KLR650; Chinese product.

“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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post #16 of 28 Old 08-15-2019, 07:37 PM
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Most automotive and heavy duty thermostats have the temperature stamped into the bulb.
The Thermo-Bob has 90C stamped in it which is 194f. I found the factory thermostat from my KLR and it has a no
temperature stamped on it.
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post #17 of 28 Old 08-15-2019, 08:22 PM
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If one looks at the wax motor bulb of Norms Chinese thermostat, one should read '90C'. I ordered 4 from Normk, to help build his initial order. Norm then turned over his contact information to Watt-man and the rest is now history.

If one installs one of Normk/Watt-man 90C thermostats into a non-bypass OEM system, then one should drill a secondary air vent / bleed hole into the outer perimeter of the 90C thermostat body. We do want some reasonable flow of HOT coolant to flow near the wax motor bulb for proper oem type operation. But Watt-man, Normk and myself would rather see a by-pass system installed with the 90C thermostats.

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post #18 of 28 Old 08-15-2019, 09:03 PM
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Quote:
Originally Posted by terry_g View Post
Most automotive and heavy duty thermostats have the temperature stamped into the bulb.
The Thermo-Bob has 90C stamped in it which is 194f. I found the factory thermostat from my KLR and it has a no
temperature stamped on it.
The Kawasaki Service Manuals list the thermostat temperature as approximately 160 degrees F. (157-162 degrees F., p. 5-3, KLR600 "Base" service manual), corroborated by pdwestman's post # 11 above.

Regardless, I'd be surprised if a clogged weep hole in a stock thermostat would cause overheating, if the thermostat opens within specifications.

BTW, my NormK thermostat has, "90 [degrees] C." stamped; perhaps suggesting it's the same component in the current KLR650 Thermo-Bob kit.

Quote:
I strongly recommend the Thermo-Bob kit. Over the long term engine life should be greatly increased.
You're in good company, terry_g! Lots of KLRistas share your opinion (including, perhaps, my '08-riding partner who will turn 100,000 miles this summer). How many additional miles do you estimate a Thermo-Bob adds to a KLR650 engine's service life?

“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre

Last edited by Damocles; 08-15-2019 at 09:17 PM.
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post #19 of 28 Old 08-16-2019, 06:18 AM Thread Starter
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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!

~Tom
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post #20 of 28 Old 08-16-2019, 07:06 AM
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But . . . did the Bar's Leaks seal the radiator?

Or, is your radiator still leaking?

From your posts, I understand the Bar's Leaks (aka, "snake oil") is the only repair/maintenance action you have performed addressing the leak.

“You better put down that gun. You got two ways to go, put it down or use it. Even if you tie me, you’re gonna be dead.” "John Russell" (Paul Newman), Hombre
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