Join Date: Sep 2017
Location: Adelaide, South Australia
My son owns a current model KLR 650. He has dropped it a few times at slow speeds in off road conditions. On two occasions when he dropped the bike on its left hand side the radiator was slightly twisted by the weight of the bike. This caused the fan shroud to press into the radiator.
The first time, the fan was locked by the friction. We were able to free the fan by twisting the radiator back, away from the fan. The radiator seemed undamaged, however, the radiator burst some months later at a point where the shroud contacted the radiator. The radiator was replaced under warranty by the dealership. Thank you very much to the that Adelaide dealership. The second time we only realized the fan was contacting the radiator when coolant started leaking out on the way home. The fan was still able to spin on that occasion. We suppose that the fan wore a hole in the radiator.
Perhaps this could be your problem? I don't know if it could happen on a 2007 bike.
It is probably worth mentioning that my son installed a popular brand of crash bars after the first incident. The second incident was in deep, soft sand. I suppose the bars were pushed into the sand deep enough to allow the bike's weight to press against the left hand fairing. The plastic left hand fairing is the only support the radiator has on that side.
As I said, these were both low speed bike drops. My son and I both own KLRs and we enjoy riding them often. However, we both have to admit that the radiator's vulnerability is a serious design flaw and weakness.
Last edited by timberfoot; 10-18-2018 at 05:49 AM.
Reason: Additional info