My Electric Fan Conversion

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My Electric Fan Conversion

Postby Gman » Sat Mar 28, 2009 4:55 pm

Warning!!!!Disconnect both sides of the battery whilst doing the modification below!!



Note:If you have warm ambient temperatures where you live use an 80 Deg C N/O switch and I've even used an 85 Deg C N/O switch successfully on one of my CX500s.It comes on a little later and shuts off just above the Temp gauge nominal mark but makes sure the fan does not stay on in hot weather :)


Note:My fan conversion does not change the cosmetics of the bike

An Electric Fan cooling system is far superior to a mechanical fan because
1:Less load on the engine.
2:Only used when required.
3:Less chance of Fan Explosion.
4:Easier to remove for servicing.
and will...
Increase performance and or reduce fuel consumption and speed up engine start-up operating temperature.


The system below and the under extreme conditions such as in the garage testing the fan kicks in around the middle of the temp gauge and then takes a couple of minutes to drive the temp down below the nominal mark and the fan to switch off.Under normal road conditions and not stopped in traffic for long the fan is hardly if ever used depending on the ambient temperatures of the day because the normal air cooling .


The wiring circuit is very simple.I took power from the Black ignition wire that runs along with the other wires on top of the Air box by cutting it and putting a connector block in there and screwing the wire I wanted into it then ran that to the dront of the bike.
I made a connector block with 3 connectors and wired it so two were connected across.
This is because at some point I'm going to fit some home-made heated grips like on my other CX so I wanted two 12v+ supplies near the front of the bike but you don't have to do this.

To the right of the After-market coil I've fitted,

Image

and then mounted it here but ignore the black wire as that's not connected to the block it's the ground/frame wire back from the temp sensor.The brown wire is the 12v+ from the rear brake wire near the air filter top that I spliced into with a connector block.This means the Efan is switched off when the ignition is off and also part of the lighting fuse circuit.

Then you put a wire into the other side of the block to the positive side of the Fan(On this fan that means it SUCKS air through the Radiator which is what we want.If you mount a fan on the front of the Radiator you will need to reverse the polarity so it blows Through the radiator.
The other side of the Rad Fan wire goes to the Thermo Temp switch and then to the frame to ground the circuit and is the black wire you see secured to the frame at the Coil bolt.

Image

I looked into this some time ago and had a partial success but wasn't happy with the Temp Switch arrangement/opening times
e.g the Electric Fan switching on too late.It was a while after I removed my attempt that I found out the temp switch I had got was not the one I wanted.It was a 90 Deg C N/O(Normally open) and I wanted a 70/75 Deg C N/O(Normally open) so I ended up putting the Mech fan back on a forgot about it until recently.

Anyway with the correct one fitted I've gone back to the project and so far testing has gone well.

The 2nd hand fan is Ducati 748/916/996 radiator FAN single fan type.These kind be found at various prices on Ebay just type Ducati Fan into Ebay.These have the correct CFM and dimensions to do the job and only draw 2 amps when in use.




When fitted to the bike the cam shaft would have needed grinding off as it was hitting a spot on the Electric fan body.
I didn't want to do this so what I did was make a new hole and brazed a nut to it on the bottom right hand side of the Radiator bracket.



Image Image

This allows the Radiator to just be a little more forward and let the Cam shaft not touch the Electric Fan body.


Recap/Procedures:

1:Small bracket to attach fan to offset side was made from some metal carpet strip drilled and bent at 90 Deg one end and bolted into hole drilled into Rad cowling.Other side was Fan tab bent and drilled and bolted.
2:Thermo Switch.Bare area at top of rad.Super glue Mating face to Rad and then Epoxy twin(Araldite) to bond secure around edges NOT on mating face.
3:Standard car spade connectors and in-line bullet connectors used for ease of removal(Auto type shops dead cheap).


Thermo Type used


75 DEG.C NORM OPEN THERM SWITCH(80 Deg C N/O if you want to fill the Radiator to the top).

http://uk.rs-online.com/web/search/searchBrowseAction.html?method=getProduct&R=0331556A

But this 85 Deg C one may be better for some people as it won't let the fan stay on too long.

http://cgi.ebay.co.uk/NO-Thermostat-Tem ... 23051ce0bc

These types of Thermo Switches come in two types N/C(Normally Closed) and N/O(Normally Open).We want the N/O type so they close when they hit the preset temperature in this case around 70/75 Deg C.
Now normally most engines temp switches/sensors use 85 Deg C but because of the Switch being mounted at the top of the RAD and not into the coolant I allowed for the slightly lower temperature it would detect.This has worked well :)


Note:You have to remove the original CX/GL Fan guard but as I never liked it anyway it's no biggy

Also I've found that if you want to fill the Radiator Full to the top you would have to put a piece of none heat conductive material between the Temp switch and the Rad before you glue it otherwise the Fan will never switch off.You could of course try a higher Temp switch like an 80 Deg C N/O switch.



I have yet to do any fuel mileage checks but the bike is definitely,"Nippier" e.g seems faster on acceleration :)


Please read this thread from another Forum as well as a Kawasaki NinJa 600 fan can be used with even less modifications,


Disclaimer:
Although I have had no problems running Efans on either of my CX500s I take no responsibility for any incorrect procedures done by anyone.
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Gman
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Re: My Electric Fan Conversion

Postby Gman » Sun Mar 29, 2009 5:44 pm

Just done 85 miles today.Not a blip.Fan never came on but then most of the riding was country roads.Very cold today over here tho'(UK) with big wind chill factor.Bike sang beautifully.

Mileage check.Got 63 to the UK gallon.Very impressed.Bike does really seem zippier.
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Re: My Electric Fan Conversion

Postby malcoops » Sun Mar 29, 2009 11:36 pm

well done shep, I have posted this onto the oz site..I will look at doing this type of mod on my next project
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Re: My Electric Fan Conversion

Postby Gman » Mon Mar 30, 2009 12:25 am

I've never liked the mechanical fan and it's fan guard.There are no disadvantages to changing over to an Electric fan and many advantages.As you are in Aus there may be a better more efficient thermo Switch system if people don't mind a bit of electronics and soldering,

http://www.heatsink.info/content.php?content=control.shtml

Just need a decent small heatsink

http://www.maplin.co.uk/Module.aspx?ModuleNo=30394

and the can be placed somewhere on top of the engine with the thermistor taped to the engine.As it's tunable the doesn't matter if it was mounted somewhere else so long as it's near an engine or radiator source of heat.You just tune it to come on to match the temp gauge needle where you want the fan to kick in.

I have the parts but have been lazy.Will get round to making one when I fit another Ducati fan to my other CX :mrgreen:

Forgot to mention.The Ducati Fans only use 2 amps when running.
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Re: My Electric Fan Conversion

Postby kentrak » Wed May 20, 2009 9:52 pm

Nice one Shep,will do this mod.while G.L.is on blocks.
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Re: My Electric Fan Conversion

Postby Gman » Wed May 20, 2009 9:55 pm

Still running great.If it works this well over the season I'll do my other CX.I hate the mechanical fans for many reasons and even Honda added Electric fans to the 650 models!! :o
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Re: My Electric Fan Conversion

Postby kentrak » Thu Jun 04, 2009 2:04 pm

Hi,Ducati fan arrived today,any problems fitting it to front of rad.so it blows? thanks,KENTRAK.
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Re: My Electric Fan Conversion

Postby Gman » Thu Jun 04, 2009 2:53 pm

Not really.My only concern would be clearance for moving the bars/Steering.Offer it up and see how it goes?Also of course it will open to the elements.You could fashion some kind of thin cover.And old Gallon Plastic oil Bottle cut to suit 1st springs to mind.Done right and painted would look ok or a bit of Alloy plate?
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Re: My Electric Fan Conversion

Postby royston » Sun Aug 09, 2009 2:23 am

Great modification, simple and effective

Thanks Roy
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Extra picture

Postby Gman » Fri Aug 21, 2009 6:51 pm

This small schematic may help as well from another CX owner,"Phil Brewer"


Image
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