I have only seen my fan on (an 09 year) when getting to the top of a sand hillclimb that was about 1/2 mile long. Seems like a lot (too much?) of radiator area for this bike, at least compared to other bikes I've had. I don't know the actual square inches of radiator, it just seems large. That's another reason I Thermo-Bob'd it...to get it to warm up faster and stay at the higher temps (circa 195 F).

 

No no, you need the fan. I've been riding in cool to cold temps and had the fan come on in intervals. It just depends on what kind of riding you're doing. I was sweeping an enduro running knarly tight single track with hill climbs in 1st gear. With the stock jetting and exhaust my KLX250 gets plenty hot when being run hard.

Road riding and casual trail riding is low load and I've never had the fan run while doing that.

I don't expect to ever have the overheat light come on unless the fan fails.

 

I wasn't riding hard at all. I was in stop and go traffic for 15 min on a 30c AKA 86f day @ about 13 min my light came on.

 

That is what i will eventually do over the winter. For now I'm just going to wire in the toggle switch.

 

This should not take any more time than replaceing the thermal with toggle switch.

You just wire the toggle in parrell with the thermal. In other words run the wire from the center of the thermal switch to the toggle and run the other wire to ground or back to the battery. This way either switch is normaly open and if the thermal is working it has a chance to close the circut and turn on the fan. Or you can do it manualy

Cheers Jim

 

The simplest of or gates.