Klr 250 overheats - Kawasaki KLR 650 Forum
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post #1 of 14 Old 05-14-2015, 07:02 PM Thread Starter
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Klr 250 overheats

Hello, new to the forum. I have an 86 klr 250 that overheats in town riding. It's fine on the highway but the stoplights kill it. The ignition has been bypassed to get it to run after the previous owner lost the key so basically it runs off of the magneto power only. The battery in it is toast and if I put a new one in there it would die from not being able to kill it. Is the ignition problem also the cooling issue or is it just a stuck thermostat?
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post #2 of 14 Old 05-14-2015, 07:32 PM
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Is the cooling fan kicking in?

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post #3 of 14 Old 05-14-2015, 07:33 PM
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And welcome to the forum

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post #4 of 14 Old 05-14-2015, 08:03 PM
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If the temperature gauge needle stays out of the far-right red zone, you're not "overheating" anything.

ALL KLR250s run off magneto AC-powered ignition; the battery is of no consequence, engine heating-wise.

Suggestion: Burp the radiator; make sure the cooling fan operates correctly.
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post #5 of 14 Old 05-14-2015, 08:59 PM Thread Starter
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What's the battery for then? I've never seen the fan kick on.
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post #6 of 14 Old 05-15-2015, 07:46 AM
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Originally Posted by eric_in_ak View Post
What's the battery for then? I've never seen the fan kick on.
No battery may mean there's no way for the fan to run.
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post #7 of 14 Old 05-15-2015, 07:58 AM
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What's the battery for then? I've never seen the fan kick on.
The battery powers all LIGHTS, in the event the engine is off, and the alternator inoperative; also, the battery powers the electric cooling fan, even when the engine is off.

The ability for lights to operate with the engine off remains a safety requirement in some (most, I'd imagine) states. For example, a night flameout on a dark road might put the bike and its rider in jeopardy, with no lights for conspicuity.

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No battery may mean there's no way for the fan to run.
Excellent point, tj!

Without extraordinary wiring changes, the absence of a battery might prevent fan operation, one might think.

The stator COULD be wired to provide 12 VDC to the battery CIRCUIT, powering the cooling fan, but . . . removal of the battery (without wiring changes) may deny that possibility.

Similarly, I'd expect no lights (headlight, tail light, brake light, turn signals) with no battery, absent some wiring accommodation.

Must study that KLR250 wiring diagram!

Last edited by Damocles; 05-15-2015 at 08:07 AM.
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post #8 of 14 Old 05-15-2015, 08:22 AM Thread Starter
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Thanks for the replies. Sounds like I need to get the wiring diagram and get the bike good and hot to see if the fan kicks on or not. I have lights when the motor is on but as soon as it's off they are all out.
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post #9 of 14 Old 05-15-2015, 08:43 AM
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Thanks for the replies. Sounds like I need to get the wiring diagram and get the bike good and hot to see if the fan kicks on or not. I have lights when the motor is on but as soon as it's off they are all out.
Chances are, your fan may be powered when the engine runs as well.

E-Z operational check: GROUND the lead to the thermal switch with the engine running; fan should rotate.
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post #10 of 14 Old 05-15-2015, 12:06 PM
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Weak/Bad battery still in system? I do hope so!

Cooling fan can NOT operate properly/efficiently with Low Voltage / Low Wattage. Runs too Slow!
Charging system / Lighting system break even point too high RPM for proper fan operation in Town, stop n go, brake light, turn signals.

Fan not needed at a steady 30-60 mph.

You need to at least get a good battery in it and a toggle switch to turn the system On and Off.

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