I purchased my first KLR a few months back, 2001 KLR650 model c. I ran into some issues on a trail 5 weeks ago, I noticed the fan was not running and the temp light was on after being stuck in some mud on our first hot day. Once home I did a bit a research via Google. Grounding the connector from the thermal switch on the rad did not activate the fans. Next I put power to the fan and was able to confirm its function. I then removed and tested the relay. The relay was no longer functioning and was replaced. Since then I have had the bike out two dozen times without the fans coming on. This model does not have a temp gauge, only a light. Unlike examples I have found on the interwebs, my radiator has what looks to be two thermal switches, one on the bottom and one up top. Grounding the bottom connector does not activate the fans. Would love to find a way to test the system. No matter what I tried, I could not get an image of the rad to upload here on the forums.

 

Got the images up.