Thermobob Modifcation

The KLR 650 has a few flaws that Kawasaki has decided that after 20 years of experience with this model, they will just ignore. One of them is the cooling system.  Cooling isn't the problem - warming and maintaining a constant temperature is.  It's a cold natured system and when temps dip below 50, the bike does not want to warm up much past the low end of the normal range, and then fluctuates wildly as you transition from highway to stopped speeds.  Anybody with basic mechanical knowledge knows this isn't optimal for internal parts - especially if you plan to keep the machine for tens of thousands of miles (which at the moment, I do as I love this bike).  

THERMOBOB By Watt-Man.

Who is Watt-Man?  Another fellow KLR enthusiast who happens to not only love the model but has made a business out of manufacturing and selling an aftermarket Thermostat/bypass system designed to keep the KLR's temps right in the middle of the normal operating range at all times - regardless of outside temp, speed, etc.  It's a time tested and proven modification that I just had to do. 

HOW IT'S DONE
The directions were very easy to follow with many great photos.  The most difficult part of the whole process is getting the plastic shrouds off and removing the gas tank.  The actualy installation of the unit was a piece of cake.  Basically, you remove the factory thermostat, and reinstall the Thermobob and bypass.  The thermobob and bypass work in conjunction to regulate the temp of coolant in the system - if it's too cold, it keeps the coolant in the engine to keep the heat in it unlike the factory set up that just kept it circulating through the whole system to keep it cold from outside air temps.  If it's too hot, it circulates it through the radiator like the factory set up did at all times to get max cooling.  Seems like such a basic concept that Kawasaki should have fixed a long time ago.  But, then again, we KLR enthusiasts wouldn't get to meet "Watt-Man" and engage in email conversations with him about our bikes then would we?

Let me tell you, after 130 miles in 45-55 degree weather riding at all different speeds, I can say that it works beautifully.  Great product "Watt-Man" (his handle on KLR.Net forums).