Not everyone who rides a KLX has common sense. Yo?
I have heard of several houses suffering burn damage by cooking a turkey in hot oil over an open flame. Seemed perfectly safe, until it isn't. Stick your hand in there, it is hot!

 

Oh man thanks for all the helpful tips guys. I'll let you guys know how it goes once the motor swap is complete.

Got stuck @ the motor side sprocket, and just picked up an impact and appropriate sized socket to zip that baby off.

 

Anyone know what state this sensor fails at? I have not been able to get the warning light to trip after running it on my bike. The fan does come on when required. It's either working perfectly, or not working at all. It would make sense that if the sensor was not giving out a reading that it would fail by displaying the warning light.

 

The high temperature sensor is normally open (N.O.) at ambient temperatures and closes at a prescribed temperature, when the engine is too hot. I'm thinking this temperature is about 240 degrees. When the sensor reaches this high temperature it closes the circuit and the warning light is energized.

I know of no way to test the sensor on the bike without intentionally over heating the bike. As robust as the KLX cooling system is, this would be hard to do.

Have you consulted the repair manual yet?

 

I briefly checked it out. I'll look at it again, thanks.

 

I figured out how to fix temperature warning switch (part No 27010-1199) if the wire is pulled of. This part is unreasonably expensive, I wasn't able to find any cheaper replacement due to the combination of a thread size (M10x1.25) and closing temp (110C deg).

Drill carefully the wire connection point (I used 1mm drill bit), screw a small screw into it, grind or cut off screw's head, then solder or connect the wire. This connection will be much stronger than by soldering only.
Checked the switch with a heat gun and multimeter, works fine.

 

That's clever

 

Used your method today to save spending $128.00. Worked like a charm. Soldered it, hit is with the heat gun and it registered continuity.

Thanks for posting this.