Cooling Fan....

[crazycoyote82]

Is this wired through the acc fuse up front? My fan has never came on. I checked the fuses and noticed that both the tail/meter was blown and the acc was blown. My tail lights and temp meter still worked however even with them blown? After I replaced them i started the bike and looked at the fuses again and the acc was blown again. Im thinking theres a short somewhere. Any guess?

[crazycoyote82]

Anybody?

[bwhittet]

The cooling fan for that year bike should NOT be powered by any of the three fuses located in the front (horn shape fuse-box) but be powered by the 30amp fuse right off the battery (white wire with in-line fuse just off battery.)

Tail/meter fuse powers speedo back-lights, tach back-lights, coolant temp back-light, running lights on front blinkers, and tail light (not brake light).
So if this fuse blows the brake light and temp gage will still work but the running lights and gage back-lights will not.

Aux fuse is just for supplying 12 volts via a white/blue stripe wire with a twin barrel style connector under the seat and one in the headlight bucket.

As far as the fan...
1st: test fan. Connect if directly to the battery with some wire. fan wires are blue and black. blue to positive black to ground. Does fan work?

2nd: Check cooling fan switch (thermo switch on bottom of radiator.) When bike is really hot this switch should be closed (conduct ohm test from spade terminal to body of switch while bike is hot. ohm should read close to "0") Or while bike is running and hot override switch by removing yellow/blue strip wire from thermo switch and touch that wire to bike frame. If fan turns on the switch may be bad or you radiator is not grounded (3rd step). If fan still does not come on then check relay (4th step.)

3rd: is radiator grounded good? There should be a ground wire going from radiator to the frame of bike. Radiator is rubber mounted and needs to be grounded. I'm not sure where the stock wire runs from and to. If you don't see one touch a wire to battery ground and to radiator while bike is running and hot. Does fan kick in now?

4th: does fan relay work? There are two relays by the battery. They are identical. Both have a square four wire connector. Fan relay has white, white, blue, and yellow/blue stripe wires (white wires should be suppling 12 volts with key on. check this). Starter relay has 2 black/white stripe, yellow/green stripe, and a black wire. Since your bike starts we know the starter relay works. Start bike. While bike is running unplug both relays and plug fan wires into starter relay. Does fan come on now when hot? You can override thermo switch as described in 2nd step while doing all this to isolate the relay for this test.

If this does not get your fan working then you have a problem in the wires or I'm missing something. Hopefully its not broken, dirty, or loose wires. Which brings me to your other question.

As far as the two fuses blowing..... yes you have a short somewhere. thats another can of worms.

I'd say start with the fan.

Good luck
Brian

[crazycoyote82]

Thank you for all the info. Now I have a good idea of where to start at and what the possibilities are. Once again, Thank you.

[crazycoyote82]

Its working now..... Not sure how... LOL

I started with checking to see if the fan still worked. It did. I then moved to the fuse by the batt. Fuse was good. However im thinking that the connector wasnt seated all the way on the wire. After pushing it together it worked great. Kicked on and off all on its own.

[razorsk8er]

The wire diagrams in the service manual are awesome for this sort of thing. FYI best 19 bucks spent.

[gazzz80s]

Hi guys i have a A3 en454 and was wondering if the starter relay and fan relay are the same relays, i know they are 12volts but one says 12V 22A but don't know what the other is and worried incase i use wrong relay!

[danoman]

Can't use the start relay, I mean you physically can't use it completely different connections