2004-2008 Radiator Fan Options - DIY?

mattwilkinson · Apr 8, 2015

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?

Thanks

Johnbo · Apr 8, 2015

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.

Oregon Trail · Apr 8, 2015

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.

mattwilkinson · Apr 8, 2015

Oregon Trail said:
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?

makazica · Apr 8, 2015

Johnbo said:
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....

mattwilkinson · Apr 9, 2015

makazica said:
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?

bushmechanic · Apr 9, 2015

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

mattwilkinson · Apr 9, 2015

bushmechanic said:
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

jmscrttndn · Apr 9, 2015

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 **** 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).

Oregon Trail · Apr 9, 2015

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.

jmscrttndn · Apr 9, 2015

Yes, my fans are screwed to the aluminum rad guard. When I remove the rad itself, the fans stay behind. Works well.

Hoosaberg · Apr 9, 2015

Get used to spending a whole weeks pay on your bike. Us old bloke have been doing that for a lifetime. That's why we have trick bikes and live in shitbox houses.

The standard fans, not sure but from memory the pre 07 KTM ones are the same, are plug and play and are thematically controlled. Makes life easy. I used to pick them up for around $140 -180 new on ebay. I live in Aus.

Otherwise you can go to a bike wreckers and see what they have from something else and wire it in. You can get a thermostat from an auto supply. You'll have to do a bit of research to find out the best temp and what fits. I put a BMW one in mine, but offhand can't remember which one.

If you trawl ebay for awhile you might find a used KTM one. Seems like plenty of people are parting out the earlier ones.

mattwilkinson · Apr 9, 2015

Oregon Trail said:
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.

As I have the AU model, my kill switch is also on my starter switch and is a toggling killswitch, Thus I can't really wire it to one of those
Those really simple one button kill switches or starter buttons on ktm's, are they a on off switch or just an off switch?

How do I check how much amperage I can use for the fan? Is it how much amperage I get out of the plug on my multimeter, or if I use a high drawing fan will it affect other things?

aaron · Apr 9, 2015

Hi Matt, nice chatting on FB the other day. If you want to do your wiring to a really high standard you are welcome to come borrow my Deutsch crimpers and I'll give you the DT spec connectors too.

Aaron 0417507875 (all my car/bike stuff is in Preston)

Oregon Trail · Apr 9, 2015

Hoosaberg said:
The standard fans, not sure but from memory the pre 07 KTM ones are the same, are plug and play and are thematically controlled. Makes life easy. I used to pick them up for around $140 -180 new on ebay. I live in Aus.

Not sure why you would hook it up "thematically" , relating to a theme?

Alot of fans will work since there is a lot of room behind the radiator. Found an old picture of my Husky an I used a switch like this.

mattwilkinson · Apr 9, 2015

aaron said:
Hi Matt, nice chatting on FB the other day. If you want to do your wiring to a really high standard you are welcome to come borrow my Deutsch crimpers and I'll give you the DT spec connectors too.

Aaron 0417507875 (all my car/bike stuff is in Preston)

Hey Aaron, I'm in Bendigo.. Thanks for the offer though! Just doing a little bit of experimenting really, It's definately not gonna be a clean install

Matt

I'll try to get a pic of the fan connector, any way to actually figure out what kind of connector I need?

Matt

FE350 · Apr 9, 2015

Spal is the manufacture of the KTM fans and they stand up well to the elements and if you search the net you can find one cheaper than buying a kit. I did this on my 2006 KTM 400. Quite simple to make a clean bracket for install and mount to existing hardware. I would run a thermostat of some sort so your not always having to switch on and off. If I am correct a BMW car thermo switch works well and is about 12 bux, I have found a few places that sell connectors that fit KTM and the Euro bikes searching online. I don't remember who I got them from when I streeted my 400 as it was quite a few years ago but do remember they were cheap. I did the fan set up for under $60 and it worked the same as the KTM hardparts fan. If you are not familiar with wiring I would be more than pleased to draw and send you a schematic for this.

FE350 · Apr 9, 2015

I also have a connector reference chart and if you get a picture on here I will cross it with a part number if I can.

mattwilkinson · Apr 9, 2015

Do all of those Spal/KTM fans have the correct bolt circle diameter? Eg. which fans would actually bolt directly my my radiator...
I actually wouldn't mind trying a high CFM pc fan, and then the proper fan when it fails to see the differences

I've heard people have actually had a great deal of success with PC fans

FE350 · Apr 10, 2015

The picture is the fan that they actually use. They have brackets for mounting that are manufactured for the specific bike. Computer fans do not have the cfm required and do not hold up to any elements what so ever. Yes they are cheap but the fail rate is very very high. The connector is very common and I will get you a part number tonight

2004-2008 Radiator Fan Options - DIY?

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