I found some inexpensive, durable, saddlebags meant for a touring or mountain bike that I want to drape over the KLX gas tank. The bags will cover the openspace between the upper and lower plastics pieces (radiator exhaust?). I plan on affixing the bags snugly to the tank and plastics to prevent rashing. Am I going to run into overheating issues? (Conditions may include stop and go traffic in 95 degF.)

 

For such a tiny engine there would seem to be more than adequate radiator cooling surface even without a lot of air flow. Still, there's only one way to find out....

BTW, it's not at all difficult to plumb a coolant temperature sender unit into a radiator hose so you can monitor this. I installed one in a Vulcan 1600 that always seemed to be running hot (and found out that it actually WAS at stoplights, but it had only slightly more radiator surface than the KLX, so that was to be expected).

The tricky part would be to find a place to mount the gauge.

 

^ Agree. Also, you should hear the fan. If its coming on a lot more, look for ways to get more airflow.

 

If your concerned about rash (secure or not it will happen if any dirt riding) cut out templates of 3M Scotchgard™ Paint Protection Film and install on plastics and exposed fuel tank areas of contact. Works great! Just listen for the fan to come on, if it never does your Good to Go!

 

I agree, clear contact paper or the like is the way to avoid damage. You will NOT be able to make them tight enough alone. It will chafe the paint. You could likely get some good 3M stuff from a sign maker shop.

I also agree, the fan will be a good indicator of getting a bit hot.

 

I almost never take off my Wolfman tank panniers (which cover most of the open area of the shroud), have no overflow bottle, and ride some steep 1st-2nd gear climbs in hot weather and have never burped a bit of coolant doing it.
Go for it. The fan is there for when you can't move fast enough to cool the radiators with air...if it comes on a lot and you have fresh antifreeze, then you need to revisit your options, IMHO.

 

Awesomely complete info! Thanks all.