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November 26th, 2005, 08:44 AM   #1
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Looking for the plan for the cooling fans

I remember that there was a post a few months ago about mounting cooling fans on your Berg. It was mostly based on a post and also general comments about how to adapt it onto a Berg.

There were part numbers with the KTM switch and also what type of toggle to get to select between "On" and "Auto".

It seems that Selco makes switches that would trigger on and off sooner than the KTM switch.

Because I have the smaller BOSS rad guards, I intend to use 80x80x15 fans, which have a cooling power of 28 CFM, compared to about 48 CFM with the bigger 92x92x25 fans, but I think that 2 of them will give the same cooling power as the regular KTM fan. 80x80x20 fans are also available but they will make the fan touch the radiator, and give one more CFM, I wonder if the fan would work better if it touches the radiator or not.

Berger, any ideas?
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November 26th, 2005, 08:58 AM   #2
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Re: Looking for the plan for the cooling fans

My 05 FS650 came stock with the electrical connector for the fan but no fan was installed. Seems like an easy plug-in after the fact.

Does anyone know if the stock fan circuit is supposed to be automatic or manual?
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November 26th, 2005, 03:32 PM   #3
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Re: Looking for the plan for the cooling fans

Hi Nic,
As I told you a couple of times already, you do not have "BOSS" radiator guards. They were made by TerryM a previous member. You guards will not work with fans. As far as fans go, I used 2 computer cooling fans and a generic 12v on/off switch. The fans are mounted in a set of BOSS radiator guards. It is a really tight fit and required alot of finess. There are a few pictures in my gallery.
The fans seem to work and hold up well, but have not been thouroughly tested.
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November 26th, 2005, 04:19 PM   #4
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Re: Looking for the plan for the cooling fans

Berger, you CAN fit a fan. I have a fan that fits, already. 80mm wide x 20 mm high. It fits nicely in these non-BOSS guards.

The cooling power is usually inferior to that of a 92 x 92 x 25 cooling fan, by about 40%.

But then I found out about heavy-duty 80x80x20 superior to regular 92x92x25 fans, in that they can have close to 50 CFM and two of those would have more cooling power than the OEM KTM fan.

I need to find out how to order these guys.

The Selco switches can be ordered according to their trigger temperature and by increments of about 5F.
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November 27th, 2005, 05:43 PM   #5
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Re: Looking for the plan for the cooling fans

My experience with fans is as follows:

I'm an East Coast, USA rider with an 05 FE 550. If my speed drops below 15 to 20 mph overheating and boil overs are on the way. Gearing is now 14/48 and I'll go to 51 on the rear when I get a longer chain. Dealer richened up the jetting. I am not sure where he wound up.

1st. experiment:

Installed 2 computer case fans (120x120x25 @110cfm each) behind the radiators. A tight fit to be sure. Ordered them from I wired the fans up as per Daleo's advice. (individually switched and fused). I just used regular automotive toggle switches and inline snap together fuses. When the temp. reached 220 deg.F I switched them both on and the temp. immediately dropped 30 deg.F. ( Temp guage from speed works.)

The fans only lasted a few minutes. I suspect that they can not stand up to the heat passing over them.

2nd experiment:

Installed 2 computer case fans(120x120x38 @ 125.8 cfm each) in front of the radiators. Fans dropped the temp right away again, but the fan blades broke off in less than a half hour. I didn't have any guards in front of them and these plastic fan blades seemed rather stiff and brittle. From the little bit they did last it is my impression that one 125cfm fan may be enough. Finding one that will hold up is another topic. Any suggestions out there?

I would reccommend that whatever fan you mount you keep it 5mm or so away from the radiator so it can run freely. Mounting it closer causes the fan to slow down as it can' t push the air between the radiator fins. Perhaps here is a clue to the overheating issue.

Also a temp gauge is a must have if you want to have any real sense of what is happening. Also, I added a switch to the gauge as it seemed to drain the battery over the course of a week.
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November 27th, 2005, 06:25 PM   #6
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Re: Looking for the plan for the cooling fans

Our problem is that the KTM fan is too big and too bulky to fit on the Husabergs as there is not enough space behind for that application.

The huskys don't seem to have the problem: ... p?t=268724

My guess is too that one fan can do the job but they are not built for automotive use.

But some fans have aluminum blades and are more resistant than others.

I will post a question on an overclocker/modders forum and see what they come with.

Obviously we need Case fans with a lot of CFM in a tight space and a motor and blade assembly that can resist the test of application.

Two smaller 80x80x15 fans with a 5mm gap may worm as they can give up to 48 CFM each at a moderate speed.
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