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April 8th, 2015, 07:02 PM   #1
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2004-2008 Radiator Fan Options - DIY?

Hi,

Who's had any experience fitting a radiator fan onto these models? I am trying to get away with this as cheap as possible, and have considered trying out PC fans etc. But am struggling to find much information on the topic...


Has anyone done this themselves using a KTM fan, or computer fans etc. ? I assume the only hassles there are if there is enough clearance between the tank and radiator and how to mount it on.


Now I don't know much about electronics and this is where I need help, I assume all the fans are 12V, correct? And all I need to do is connect it to a 12V power supply somewhere on the bike... Now, where can I get that from? are there any free power connectors on the bike anywhere? 2007 FE 550 by the way.

If I was to splice it into something like the headlight, would it drain too much power for the headlight to work efficiently? As I said I have no idea about batteries. Absolutely 0 idea... When the bikes running, do the headlight etc. get powered directly from the stator? Or are they powered by the battery which is then charged the the stator?

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April 8th, 2015, 08:25 PM   #2
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Just fitted a Trail Tech digital fan unit to my FE570, works a treat and is super easy to fit! Seems like several of the 4 stroke machines use the same radiators.

I hard wired mine direct to the batter - cable is literally just long enough to do the job and is fused. CAN$200 for the kit.

Has a small digital screen to allow you to adjust the temp at which the fan kicks in as well as change from centigrade to fahrenheit etc.
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April 8th, 2015, 09:57 PM   #3
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I have used 2 of these fans and switches, one on my KTM and the other on my 07 450 Husaberg. I wired the fans so I can control them manually. I wired the fan on top red switch and the electric start on the bottom gray. For the fan I just found a hot 12v connector on the harness. I think each set up cost me under $40.

New Universal Motorcycle Fan KTM Honda Yamaha Suzuki Kawasaki | eBay



I switch I used.

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Last edited by Oregon Trail; April 8th, 2015 at 10:00 PM.
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April 8th, 2015, 10:40 PM   #4
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Originally Posted by Oregon Trail View Post
I have used 2 of these fans and switches, one on my KTM and the other on my 07 450 Husaberg. I wired the fans so I can control them manually. I wired the fan on top red switch and the electric start on the bottom gray. For the fan I just found a hot 12v connector on the harness. I think each set up cost me under $40.

New Universal Motorcycle Fan KTM Honda Yamaha Suzuki Kawasaki | eBay



I switch I used.

Looks sweet, How did you mount up the fan to the radiator?
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April 8th, 2015, 10:58 PM   #5
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Originally Posted by Johnbo View Post
Just fitted a Trail Tech digital fan unit to my FE570, works a treat and is super easy to fit! Seems like several of the 4 stroke machines use the same radiators.

I hard wired mine direct to the batter - cable is literally just long enough to do the job and is fused. CAN$200 for the kit.

Has a small digital screen to allow you to adjust the temp at which the fan kicks in as well as change from centigrade to fahrenheit etc.
He's talking about older models, 2004-2008....


Matt, since your bike is 2007-08, you might have more room than 2004-2007 models and also mounting points on the radiator.

I personally wouldn't spend money and time on PC fans....
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April 8th, 2015, 11:27 PM   #6
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Originally Posted by makazica View Post
He's talking about older models, 2004-2008....


Matt, since your bike is 2007-08, you might have more room than 2004-2007 models and also mounting points on the radiator.

I personally wouldn't spend money and time on PC fans....
I figure a PC fan will cost around $10-15 tops, a switch simply $2 off eBay, and if I go with a proper fan that'll cost me around $200 in Australia, and as a teenager that's a weeks wage!

My bike doesn't have any of the road gear on it, Would it be possible to connect up the fan to one of the spare indicator plugs? Are they 12V?

Last edited by mattwilkinson; April 8th, 2015 at 11:29 PM.
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April 9th, 2015, 02:11 AM   #7
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a 12v fan will at least need to be connected to the regulator output

if you still have the battery the 12 reg wire is easy to find it just goes (eventually) to the battery +

if you don't have a regulator or battery need to buy a regulator and connect it to the AC output of the stator

the factory fan is located on the RHS lower corner of the rear side of the radiator and comes with 4 plastic plugs you push into the radiator fins from the front side.

fan then mounts with self tappers threading into the plugs
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April 9th, 2015, 03:16 AM   #8
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Originally Posted by bushmechanic View Post
a 12v fan will at least need to be connected to the regulator output

if you still have the battery the 12 reg wire is easy to find it just goes (eventually) to the battery +

if you don't have a regulator or battery need to buy a regulator and connect it to the AC output of the stator

the factory fan is located on the RHS lower corner of the rear side of the radiator and comes with 4 plastic plugs you push into the radiator fins from the front side.

fan then mounts with self tappers threading into the plugs
I actually found a 2 pin connector with a red/yellow and brown wire. On the diagram in my manual it says that that connector is for a fan... So I assume that would be the go?


Would it be best to get a male version of that connector and solder the fan wires onto it?
I'm not sure what kind of connector it's called, because in the manual it doesn't give any indication or lettering....


One more thing, how much power do you think the fan could use? I don't want it to draw too much power...

I do still have my battery, I presume also have the regulator? I've never touched it
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April 9th, 2015, 03:39 AM   #9
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Food for thought (not that it will help in your case)... someone before me wired my fans to come on when the left turn signal is on (I have no turn signals, just the handlebar switch)... Kind of a shit way to do things since now I have to re-wire the fans if I want to add signals. Oh well.

Whatever you do electrically, please don't simply cut the wires. Any wiring you do... add labels to know what the wires are and give yourself enough room so that you can revert any changes made if you want/need to in the future.

Why do I say this? The guy before me went around with wire cutters and cut stuff at random leaving me with a mess of very short, very confusing wires.

I think next winter will see me completely rewiring the bike (well cutting and re-routing the existing harnesses anyway).
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April 9th, 2015, 06:21 AM   #10
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You can find fans made for dirt bikes or OHV's fairly inexpensive, if you buy a computer one, they are not made for the elements......I used that switch because I didn't want to have too many switches on my handlebars. I mounted the fan with zip ties, you can uses plastic screws also.
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