So as I was taking the radiator out, I ended up pulling the wire off the water temperature warning switch.

In an attempt to solder it back together, I cut off a bit of the pink on the top of the switch and exposed some of the metal jacket that holds the wire in place. I did a continuity check, and found that the jacket and the inner wire are connected, and I am going to solder the wire back to the center/metal jacket in order to get a strong connection, and then wrap it with heat shrink to seal the deal.

Anyone have any better ideas? I'm trying to save the approx. $150CAD it is for me to purchase a new switch.

Also, anyone have ideas on an easy way to test the switch with a multimeter?

Thanks in advance!

 

Do you know what temp the unit is to activate?
It is a simple test with a multi meter, just set it on 'continuity' or 'ohms' and listen or watch the needle.
Now how your going to get the unit to that temp is another issue. Boiling water if it is below 212F or oil if over. Oil is going to be dangerous at that temp with an open flame.

I would just throw it away or not worry about it. How many times has your bike overheated? Mine, never.

 

If the temp is known it may be possible to find an automotive unit to work.

Or find one from the following - according to parts sources these are the bikes that use the same unit as found on Partzilla:

This Kawasaki 27010-1199 SWITCH,WARNING is used on these models and components:

1986 ZX1000-A1 Ninja 1000R RADIATOR-FAN-WATER PUMP (-E-NO. 003101)
1987 ZX1000-A2 Ninja 1000R RADIATOR-FAN-WATER PUMP (-E-NO. 003101)
1993 KLX650-C1 KLX650 RADIATOR
1994 KLX650-C2 KLX650 RADIATOR
1995 KLX650-C3 KLX650 RADIATOR
1996 KLX650-C4 KLX650 RADIATOR
2006 KLX250H6F KLX250S RADIATOR
2007 KLX250H7F KLX250S RADIATOR
2009 KLX250T9F KLX250S RADIATOR (T9F-TAF)
2009 KLX250W9F KLX250SF RADIATOR
2010 KLX250TAF KLX250S RADIATOR (T9F-TAF)
2010 KLX250WAF KLX250SF RADIATOR
2011 KLX250TBF CANADA ONLY RADIATOR (TBF-TDF)
2012 KLX250TCF KLX250S RADIATOR (TBF-TDF)
2013 KLX250TDF KLX250S RADIATOR (TBF-TDF)
2014 KLX250TEF KLX250S RADIATOR

 

First place I would try would be eBay to look for a used one. They rarely go bad and you can test it before installing.

It's not that difficult to test in hot oil. I last used a Coleman single burner stove to heat motor oil in an old coffee can. It's no more dangerous than deep frying hush puppies. In fact, it might be cheaper to use cooking oil instead of motor oil. Water won't work. It boils at 212, which is lower than your switch limits. You do need a fairly accurate thermometer, however. I took the temperature up and down several times to get a more accurate reading. The testing procedure is described in the KLX service manual.

Good luck.

 

100 degrees C (212 F) the fan comes on according to my Vapor

 

So you did this in the back of the van or your house?
I would consider that dangerous, especially if the van... or the house are moving!

 

Nothing dangerous about it. I deep fry the Thanksgiving turkey in the RV every year while we're going down the highway to grandma's house with the wife driving. I do, however, get a new RV each year.

 

All joking aside, what's the difference between heating motor oil up to say 350°F and doing the same with cooking oil to make french fries or wings?

All seriousness aside, I'd use cooking oil and test the switch while cooking some wings and fries. Make some snacks.

 

FYI, Coleman single burner stoves are generally used for camping, which usually takes place outside.

Common sense.

 

Wrong sensor/switch. We're talking about the high temperature warning light sensor, not the fan switch.