05-06 Plastic Swap

jdfowler0 · Feb 26, 2015

Hey guys, I have a 2006 FE 650 with factory rad fan, and have found a full set of black plastics and tank off a 2005 at a reasonable price. I really would like to move to black rather than the Yellow and Blue mismatch. I'm 99% certain that all the plastics and tank will bolt on without issue, but I'm wondering if the rad fan will clear the older 05 tank. I've read different things.

Also, will an 05 seat fit no problem?

Thanks!

Huskyfatman · Feb 26, 2015

The '05 and older tanks hinder air flow to the radiator and wouldn't clear the fan, which was the reason for the re-design. That's what I was told in '06, but never tried to put a fan on my '05. It ran much cooler with the Clarke tank though, so I can confirm the air flow claim.

jdfowler0 · Feb 26, 2015

I have heard those reports....It's not easy to source aftermarket goodies for these older Berg's....certainly here in Canada. But I've know of an 05 FE650 that is being parted out.

I'm gonna take the rad guards, case guards, fuel tank and all the plastics.

Does anyone foresee any issues concerning fitment on my 2006 FE650? Everything should bolt right up....right?

Does it make sense to install an 05 tank and shrouds if it impedes air flow, and impedes the installation of my Hard Parts Rad Fan?

Idle · Feb 26, 2015

I've got an 05 with an 06 tank. I have no fan.

Iirc, I had to reposition the hose clamp on the T-stat as it rubbed the 06 tank.
Your fan, I'm almost positive wont fit with the 05' tank.

I picked up the 06' tank for more range as it holds 10.5L vs 9L for 05. (2.8 vs 2.3 gallons). So there's that to consider as well.

No discernible difference fitting the seat on either tank.

c337b · Feb 26, 2015

The fan will not fit with the older tank. I upgraded my 2004 to a 2006 tank so I could install a fan Seat fits fine
Note: the rad does not have the fitting for the thermostat for the fan I also upgrade to a 2006 rad

jdfowler0 · Mar 10, 2015

Thanks for the replies, I've now developed a couple more questions. The 05 tank is on its way, so I've commited to moving to a tank that impedes air more and eliminates the use of my fan , simply because of the colour. Silly...maybe. There should be enough room to install a thin PC/Computer fan right? Should be very simple given I alresdy have the harness and thermostat.

Also, will my 06 kick start lever fit the older 05 style tank without issue? My understanding is that the older bergs had a longer kick starter, so my 06 starter lever should clear it no problem right?

Has anyone ever had rubbing issues on their 06-08 kick start lever on the bottom of their 06-08 tanks? My current stock setup on my 06 berg 650 is a tight fit and is actually eroding the bottom of the tank away a bit.

Huskyfatman · Mar 10, 2015

Kicker should fit. When I bought my '05 as a leftover "Euro" model it came with the redesigned '06 pipe and kicker. The pre '06s had tire clearance problems with the header, so the '06 got a redesigned pipe which required a Kick starter redesign. My bike came with the newer pipe and kicker in the crate and cleared the '05 tank fine.
Here's my 2005 with '06 pipe and curved kicker compared to the older style header and straight kicker.

jdfowler0 · Mar 11, 2015

Excellent info! Thanks a lot. Thats the answer I was looking for. Any ideas on the PC fan? I plan to run Engine Ice in her too.....to help with the heat. Last season I had the fan running all the time, much more often than on my EXC450. I figure Taffy's Jet Kit will help the bike run a bit cooler as well.

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05-06 Plastic Swap

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