I went a different route with plumbing for heated handlebars and thought I would share. I figured I would leave the factory thermostat that the bike came with. (wifes 23 250xc, my 24 300xc). If there was a nice bolt in thermostat setup available like on the four strokes I would consider switching to that... I didn't want to mess with trying to tap into coolant hoses. I have done that on previous bikes (2 Stroke) I wanted something with a cleaner install. On the TBI bikes the cylinder head cover and water pump cover are super cheap. Like $30 for a head cover and $10 for a water pump cover from the dealer. So I decided to drill and tap them both for my supply and return lines. I figured if it didn't work like I wanted I'm only out $40 to go back to stock. I felt comfortable with amount of material when threading the parts, and so far no leaks... For these 2 strokes I think a billet head cover with the thermostat integrated in and a couple ports for things would be the perfect setup. Till then this is working great and is basically free minus your time and some fittings.
I also modified both our stock bars, and turned them into heated bars. First time doing that, not hard just take your time. All in for both bikes im about $50 in materials.
I also modified both our stock bars, and turned them into heated bars. First time doing that, not hard just take your time. All in for both bikes im about $50 in materials.
