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Discussion Starter #1
My radiator fan does not get 12volts to turn on when i short the therm switch that is screwed into the bottom of the radiator. I assume this would fool the circuit into energizing the fan, but notta.
Things I know: 1. The 15a fuse is good. 2. There is no 12v upto the fuse when the therm switch is shorted

I think there is a relay somewhere that may be needed to turn the fan on but do not know where it is located?

Any ideas. Also, i seem to remember seeing on this site where someone had 'created' a readable schematic but I can not find that posting anywhere now.

Thanks
 

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Generation 1, or Generation 2?

Generation 2's don't have no stinkin' fan relays.

If a Generation 1, you have an identical ride-along relay you can substitute, the starter circuit relay (NOT the starter relay).

You can Google, "KLR 650 Wiring Diagram," and "2008 KLR 650 wiring diagram," for links to full-screen schematics.
 

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gen 1 has a fuse on the right side by the overflow bottle for fan. 10 amp I think. Mine had a spare built in. thanks to whoever thought that up. Make sure the fan shrout is not interfering with the fan. This can happen when dropped on left side. Which can happen if you are loaded down for a trip to alaska and park in soft soil on the Denali highway.:t1202:
 

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My schematic shows the power feed to the fan fuse also powers the instrument lights.
Are these lights on? If yes, you may have a broken wire.
 

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My schematic shows the power feed to the fan fuse also powers the instrument lights.
Are these lights on? If yes, you may have a broken wire.
On Generation 1 (through 2007) KR650's, the 10-amp fan fuse does not protect instrument lights, according to this wiring diagram as I read it; rather, the fan fuse is in'line to the constant + 12 VDC line (WHITE) feeding the fan relay:

http://www.bigcee.com/faq/KLR650-color-wiring-diagram.jpg

With a blown fan fuse on these models, only the fan should be disabled; all other electrics (including instrument lights) functioning. For testing, grounding the thermal fan switch lead (bottom of radiator) should activate the fan relay and turn on the fan on these models.

On Generation 2 KLR 650's (2008 and later models), the 15-amp fan fuse feeds switched + 12 VDC (BROWN) to the fan switch only, the fan switch when activated feeds + 12 VDC to the fan motor, the fan motor is permanently grounded [a different scheme from Generation 1 circuitry; Generation 1 fan switch feed a GROUND to the fan relay; Generation 2 fan switch feeds switched + 12 VDC to the fan motor]; similarly, loss of the fan fuse on these models means only, no fan; all other electrical circuits (including instrument lights) should be unaffected:

http://media.photobucket.com/image/klr 650 wiring diagram/RobertKLR/odd%20things/2008klr650corrected.jpg

(I'll try to post an image of the '08-and-later wiring diagram):



Grounding the radiator fan switch manually on a Generation 2 KLR650 will not activate the fan motor; could blow the fan fuse. Shorting the two leads of the fan switch should turn on the fan.

Instrument lights should be powered by SWITCHED + 12 VDC, "upstream" of the fan circuit.

BRIEF NOTE: Very early KLR650's had no fan fuse; think it was added in the 1990's.

---------------------------

Back to basics, basement: What YEAR is your KLR650?

In summary; Generation 1 thermal fan switch provides ground, activating fan relay and consequently, fan.

Generation 2 thermal fan switch, when activated, provides full current + 12 VDC to fan motor (motor hard-wired ground).
 

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Oh, NO!

WHAT have I DONE?

Did I KILL the THREAD?

I HATE it, when that happens!

How can I bear this on my conscience?

Still wonderin',
Back to basics, basement: What YEAR is your KLR650?

In summary; Generation 1 thermal fan switch provides ground, activating fan relay and consequently, fan.

Generation 2 thermal fan switch, when activated, provides full current + 12 VDC to fan motor (motor hard-wired ground).
I'd add, in summary: Test Generation 1 fan by shorting thermal fan switch lead to ground; if fan does not come on, check fuse, fan relay, fan motor, in that order.

For Generation 2, test fan by shorting across thermal fan switch terminals; if fan does not come on, check fuse, fan motor, in that order.

I have spoken! :)
 

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Discussion Starter #8
Found the problem. Rider induced issue. Some time ago i had installed a manual fan switch in parallel with the fan switch mounted on the radiator. And rather then soldering the wires I instead used those cheater piggy back plastic connectors that clamp around the existing wiring, and cutting through the insulation to make the contact. Well, over time this connector vibrated open then not allowing the fan to turn on with either my manual switch or the rad switch.
Removed these POS connectors and soldered my wires together, now all is good.
Thanks for the input guys and also for the great wiring diagrams, i will definitely save in my files.
 

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Lone Rider
Quote: “On Generation 1 (through 2007) KR650's, the 10-amp fan fuse does not protect instrument lights, according to this wiring diagram as I read it; rather, the fan fuse is in'line to the constant + 12 VDC line (WHITE) feeding the fan relay: “

Larry31
Quote: “My schematic shows the power feed to the fan fuse also powers the instrument lights. “

Sorry for any misunderstanding. I meant the feed to the fuse, not the fuse powering the lights.
 

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okay, team after reading a substantial amount my simple question is . . . has anyone shrink wrapped the wire aft of the radiator fan switch on a Gen1. My fan seems to work properly, but if i touch the wiring it seems to be held by a thread. any advice appreciated. line6
 

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Can you not just light squeeze the dis-connected terminal with pliers to increase the grip of the terminal?

Has anyone figured out how to Delete a posting? Guess I'll go to FAQ.
 

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Sorry about that, I didn't realize that we were in the Gen 2 column.

Use a pocket knife or small screw driver to flex the terminals inside the multi-plug to achieve a tighter grip.
 
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