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KLR650 Gen III 2022 Onwards Thermo-Bob Complete Kit


KLR650 Gen III 2022 Model onwards

The 2022 KLR still has the same cooling system layout as all previous KLRs (no bypass and a 158°F thermostat) so it still benefits from a Thermo-Bob.  One big change for 2022 is the lack of instrumentation – these new bikes don’t have a coolant temperature gauge anymore, or a tachometer.  We’ve generated new products to allow you to get those instruments on your bike if you’d like, so see any of the 3 options below:

Option 1: Use a Thermo-Bob 2 without adding extra gauges ( $229.95 )

The Thermo-Bob 2 that we’ve sold for years also fits the 2022. Go to Thermo-Bob under this same KLR650 category ‘engine’ HOWEVER we recommend this new specific kit for the new gen III 2022 model.

Option 2: Use a Thermo-Bob 2A with a temperature port for a future temperature gauge installation ( $279.95 )

We have the new “Thermo-Bob 2A” which is machined differently from the Thermo-Bob 2: this model includes a threaded port for a 1/8-28 BSPP temperature sensor.  In this $50 upgrade from the base Thermo-Bob 2, your kit will use the different housing (with a removable plug in the port).  This way, you can install the kit now and purchase a temp gauge later, whose sensor will screw into the Thermo-Bob 2A’s housing.

Option 3: Use a Thermo-Bob 2A with a digital temperature gauge ( $389.95 )

This is a complete kit and the most popular: The Thermo-Bob 2A complete with a Trail Tech digital temp gauge, a template for installation plus the black, stainless mounting hardware.


NOTE – There’s also an option for those who want to add a digital tachometer. Go to category ‘lighting/electrical’ where you will find a Trail Tech digital tach/hour meter at a hot price of $89.95.




This kit fits all years of the KLR600 and KLR650, but is directed at the 2022 KLR as the bike does not have a coolant temperature gauge from the factory.  This kit utilizes a modified Thermo-Bob 2 called the “2A”, which is machined differently to add a port for a temperature gauge.  The kit includes a Trail Tech digital temperature gauge plus a drilling template to mount it properly on your 2022’s dashboard, just below the factory instrument panel.  It also includes black, stainless attachment hardware for a professional look that mimics the factory layout.  A Trail Tech digital tachometer is a $84.95 option.

Kawasaki cut corners in the KLR cooling system, and the Thermo-Bob modifies your cooling system to operate like automotive systems have for decades.  In stock form, the KLR runs too cool when ridden in temps below about 80 – 85F. The cooler outside it is, the worse a stock bike is. Plus, the factory cooling system relies on surges of cold coolant every 30 seconds at the bottom of the cylinder to control engine temperature… just look at the plots of actual measured temps.

The Thermo-Bob is a machined, hard-anodized aluminum external thermostat with a coolant bypass. It allows coolant to bypass the radiator during warm-up, speeding warm-up and eliminating the surges of cold coolant year-round. It also raises the operating temperature at the top of the cylinder to 195°F from 158°F… more importantly, it raises the operating temperature at the bottom of the cylinder to 185°F from downright cold, (I’ve measured temps below 30°F).   It should eliminate the out-of-round cylinders that are common to the KLR as it ages which usually results in increased oil consumption. I’m at 184,000 miles on my KLR with a Thermo-Bob and have never rebuilt the engine…  the bike burns about 10 oz. of oil every 1,000 miles.  The warmer temps should extend engine life as well as increase oil change intervals, and improve economy by a few MPG. It was the first product to ever receive a 10-out-of-10 rating at Patman Racing, and was strongly recommended by the late Cary Aspy, who was the original developer of the 685 and 705 KLR big-bore kits. Cary also liked how this gave more consistent carburetor jetting.

A full technical write-up can be found here.





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Additional information


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