Repair a Fan Switch
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- Mark King
- Silver Member
- Posts: 910
- Joined: Fri Jun 26, 2009 5:55 am
- Location: ON, Canada
Repair a Fan Switch
You might be able to repair your current fan switch by simply cleaning it with vinegar. Especially in older bikes that sit, or have sat sometimes for years, the switch can become gummed up and stuck.
The switch is actually three pieces and the end cap is removable.
Because this part sits in the coolant it attracts the same gunk that plugs your rad.
Easy step by step process - and I'll add pics below when I remember how to do it.
1. After the switch is removed from the bike it is best to soak it for a few hours in a straight vinegar bath. This helps break up any corrosion that has accumulated on the threads that hold the end cap.
2. Firmly grip the main body of the switch - I used a hand held pair of vice grips where the wrench would normally go.
3. DO NOT GRIP OR TURN THE END PROBE - WHICH IS THE COPPER PIECE ON THE END.
4. Underneath this end probe, there is a small and very short shaft and then a slightly larger piece. In profile there are eight distinct sections of the switch. You are looking for the third distinct piece counting the end probe as number one. (Shown better in the photos)
5. Grip this third section with a needle nose vice grip and turn it gently to unscrew it. It will take some effort but not much. If you are stripping metal off it like I did at first, it probably needs to soak longer.
6. Once the end piece is removed you will see a pin that is supposed to slide freely inside.
7. Soak the end piece with the pin in vinegar overnight and it should loosen enough to pull the pin out. If not, let it soak some more.
8. When the pin is removed, use your fingernail to scrape off any more residue that may be stuck on it and clean out the hole where it sits. I used a toothpick and vinegar bath.
9. Once clean, the pin should slide very easily in and out of the hole.
10. Re-assemble.
11. Test, or not, to suit but should probably test as this will only work if the switch is broken because the pin is stuck.
Hope the pics attached ok. If not I will add them again later.
The switch is actually three pieces and the end cap is removable.
Because this part sits in the coolant it attracts the same gunk that plugs your rad.
Easy step by step process - and I'll add pics below when I remember how to do it.
1. After the switch is removed from the bike it is best to soak it for a few hours in a straight vinegar bath. This helps break up any corrosion that has accumulated on the threads that hold the end cap.
2. Firmly grip the main body of the switch - I used a hand held pair of vice grips where the wrench would normally go.
3. DO NOT GRIP OR TURN THE END PROBE - WHICH IS THE COPPER PIECE ON THE END.
4. Underneath this end probe, there is a small and very short shaft and then a slightly larger piece. In profile there are eight distinct sections of the switch. You are looking for the third distinct piece counting the end probe as number one. (Shown better in the photos)
5. Grip this third section with a needle nose vice grip and turn it gently to unscrew it. It will take some effort but not much. If you are stripping metal off it like I did at first, it probably needs to soak longer.
6. Once the end piece is removed you will see a pin that is supposed to slide freely inside.
7. Soak the end piece with the pin in vinegar overnight and it should loosen enough to pull the pin out. If not, let it soak some more.
8. When the pin is removed, use your fingernail to scrape off any more residue that may be stuck on it and clean out the hole where it sits. I used a toothpick and vinegar bath.
9. Once clean, the pin should slide very easily in and out of the hole.
10. Re-assemble.
11. Test, or not, to suit but should probably test as this will only work if the switch is broken because the pin is stuck.
Hope the pics attached ok. If not I will add them again later.
Last edited by Mark King on Tue Aug 23, 2011 3:40 pm, edited 1 time in total.
M King
1977 GL1000 - Under s l o w restoration
1981 CB900C - Rebuilt but stripped spark plug thread
2002 VTX 1800 -Current Rider
1984 GL1200 Aspencade - Restored and Sold
1980 Suzuki GS850G - Restoration on hold
1985 750 Nighthawk SC - Sold
1976 GL1000 - Yellow - Restored and Sold (regret the sale)
1981 GL1100 - Naked - Restored and Sold
1977 GL1000 - Under s l o w restoration
1981 CB900C - Rebuilt but stripped spark plug thread
2002 VTX 1800 -Current Rider
1984 GL1200 Aspencade - Restored and Sold
1980 Suzuki GS850G - Restoration on hold
1985 750 Nighthawk SC - Sold
1976 GL1000 - Yellow - Restored and Sold (regret the sale)
1981 GL1100 - Naked - Restored and Sold
- sunnbobb
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Re: Repair a Fan Switch
I'll be dad-gummed! That is a fine little tutorial, thanks bunches!
I found the end of the internet
---- Bradshaw Bikes custom polishing for your wing. Visit us on facebook!
1978 Learning Experience
1980 County Road Hauler "Brain Damage"
1978 Cafe Custom Gl1000 "Vyper"
1977 Bulldog Inspired "Vaincre"
1981 Street Fighter GL1100 "No Quarter"
1983 Supercharged Street Drag "Anubis" (in worx)
1983 gl1100 mint restoration "Kristen"
1985 Aspencade..pondering.
---- Bradshaw Bikes custom polishing for your wing. Visit us on facebook!
1978 Learning Experience
1980 County Road Hauler "Brain Damage"
1978 Cafe Custom Gl1000 "Vyper"
1977 Bulldog Inspired "Vaincre"
1981 Street Fighter GL1100 "No Quarter"
1983 Supercharged Street Drag "Anubis" (in worx)
1983 gl1100 mint restoration "Kristen"
1985 Aspencade..pondering.
- Roady
- Member Relations &_Graphics
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Re: Repair a Fan Switch
I had no idea ...
Worth trying on the old one (which never got thrown out, of course).
Worth trying on the old one (which never got thrown out, of course).
- JBz
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Re: Repair a Fan Switch
my experience is the bottom contacts stay good. The top piece with the powdery stuff in it goes bad or collects moisture past its special seal and messes things up like the sliding pin. i cut one top piece apart in the lathe to take a look . If just the top part that screws out was available I imagine most could be saved. JB
jbz........... Thinkin about sh-t too hard and You wont get anything done
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- Cast Iron Member
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- Location: Atlanta GA
Re: Repair a Fan Switch
Having some trouble on this very thing and I'm a long way from home. Does any one have part numbers for the automotive ones that fit?
- ericheath
- Honored Life Member
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- Joined: Wed Jul 29, 2009 11:20 am
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Re: Repair a Fan Switch
FAN SWITCH
roady did the research for this, i didnt see it here in this list so here is the link to his post. octane posted the interchange list and it will fit a bunch of gl's.
http://www.ngwclub.com/forum/viewtopic. ... 3965#63965
here is the link to rock auto
http://www.rockauto.com/catalog/raframecatalog.php
click on part number search
here is the part number
2011614
timma11
roady did the research for this, i didnt see it here in this list so here is the link to his post. octane posted the interchange list and it will fit a bunch of gl's.
http://www.ngwclub.com/forum/viewtopic. ... 3965#63965
here is the link to rock auto
http://www.rockauto.com/catalog/raframecatalog.php
click on part number search
here is the part number
2011614
timma11
Whatever I suggest here should be given ample time for a moderator to delicately correct. I apologize in advance.
77 WING, 1200 engine with 77 heads, cams, gl1100 foot pegs, Magna V65 front end, 764A carbs, [-gone Suzuki M109 monoshock--, replaced with gl1100 shocks] gl 1200 swing arm, gl1500 final drive, wheel and rear brakes Valkyrie seat, Meanstreak tank, Sportster pipes, Power Arc ignition off crank.
77 Wing. black
83 Wing, in pieces
"Continuing education is important even if the subject matter is fairly useless (as in this case)."---Greg Foresi
77 WING, 1200 engine with 77 heads, cams, gl1100 foot pegs, Magna V65 front end, 764A carbs, [-gone Suzuki M109 monoshock--, replaced with gl1100 shocks] gl 1200 swing arm, gl1500 final drive, wheel and rear brakes Valkyrie seat, Meanstreak tank, Sportster pipes, Power Arc ignition off crank.
77 Wing. black
83 Wing, in pieces
"Continuing education is important even if the subject matter is fairly useless (as in this case)."---Greg Foresi
- lt1
- Titanium Member
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- Location: AZ
Re: Repair a Fan Switch
Doing the vinegar soak in combination with an ultrasonic cleaner may speed up the process.
82 GL1100 Standard/RatBike
83 GL650 Interstate
83 GL650 Interstate
- Wingerinsandiego
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Re: Repair a Fan Switch
Great tutorial Whiskerfish! I am getting ready to check the temp sensor which is down line from the fan switch. Would be great to see a step by step on how to get to (right now I may have to remove the carbs) if it is repairable, etc. My temp guage is not working and this sensor is where hopefully my adventure ends. Thanks
1976 LTD
1985 LTD (SOLD) To support my naked obsession!!
I don't want a nickel, just want to ride my motorcycle!
1985 LTD (SOLD) To support my naked obsession!!
I don't want a nickel, just want to ride my motorcycle!
- fish
- SUPER BIKER!!!!
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Re: Repair a Fan Switch
mark thank you.
I just did this on a friends bike & it was a FIX!
I just did this on a friends bike & it was a FIX!
Timothy Mark Fisher
Catalina Arizona
"ride it.. don't be one of those guys who will fix it 'til it's broken" (JDVorchek)
"It is not logic or economics that drive a motorcyclist but passion!" (bugdaddy66)
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Catalina Arizona
"ride it.. don't be one of those guys who will fix it 'til it's broken" (JDVorchek)
"It is not logic or economics that drive a motorcyclist but passion!" (bugdaddy66)
"I fully agree with fish, well at least 27% of the time."(Casper)
"Why do you have to ruin a perfectly good thread with common sense"(Placerville)
"my best guess for an answer would be a stream of complex expletives" (Transitman)
"I like a cold beer with my beer" (OldeWing)
"Most of us like the sport of wrenching too." (fred camper)
"Now go ride the heck out of it, til mother says do your chores"(Gowing)
"I agree with Fish" (Salukispeed)
- djoyner
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Re: Repair a Fan Switch
I know this is an old thread, but I wanted to thank Mark for this tutorial. I picked up a '79 about a month ago and noticed that the PO hand installed a switch to active the radiator fan. I followed the excellent directions and the switch works great now.
Thanks again...now onto rebuilding the carbs.
Thanks again...now onto rebuilding the carbs.
D J
Visit me at http://www.dennisjoyner.net
'78 GL1000
'82 GL1100I
'85 GL1200I
'95 GL1500I
'06 VTX 1300S
'06 GL1800
Visit me at http://www.dennisjoyner.net
'78 GL1000
'82 GL1100I
'85 GL1200I
'95 GL1500I
'06 VTX 1300S
'06 GL1800
- tlbranth
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Re: Repair a Fan Switch
Waaaaaaaah. No pics.
Terry
Don't own a Vanagon
Don't work at Boeing
Life is good
1999 GL1500 SE
2002 Honda VT750 "ACE"
1975 GL1000
1970 CB750
Don't own a Vanagon
Don't work at Boeing
Life is good
1999 GL1500 SE
2002 Honda VT750 "ACE"
1975 GL1000
1970 CB750
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- Cast Iron Member
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- Joined: Sun Jun 03, 2018 10:27 pm
- Location: Belmont West Virginia
Re: Repair a Fan Switch
Great write up. I had a little trouble finding the right set of pliers to grip the part tight enough to break it loose. No needle nose vise grips to use so let's improvise. I scarred the thing up slightly with a few pairs of needle nose pliers and she would not budge. Looked around for something better and found a set of cheapo wire crimp/strippers that were actually the hot ticket for this. The screw driver is pointing at the part I used and is partially covering the marking saying "ignition terminals"
As of now it's all soaking in vinegar.1978 GL1000 My 1st GL Learning experience
2000 Kawasaki Nomad 1500
2000 Kawasaki Nomad 1500
- salukispeed
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Re: Repair a Fan Switch
That portion on Those crimpers are for crimping on the old style spark plug wire terminals like we used to push down in the coil and distributor caps back in the day before electronic ignition, Old school stuff
Honda 72 CL100 sold
74 CB750 K4 nice driver
1966 CA77/305 Dream nostalgic driver
84 GL1200I work in progress
1970 CT 70
1982 GL500 Interstate
74 CB750 K4 nice driver
1966 CA77/305 Dream nostalgic driver
84 GL1200I work in progress
1970 CT 70
1982 GL500 Interstate
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- Location: Belmont West Virginia
Re: Repair a Fan Switch
If I'd have tried them 1st I might not have scarred the part up as much. I didn't hurt it with the other pliers. If you are doing this job and have those handy they work really well for this application.
1978 GL1000 My 1st GL Learning experience
2000 Kawasaki Nomad 1500
2000 Kawasaki Nomad 1500
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- Rusty Probie
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Re: Repair a Fan Switch
Thank you for the info. Mark King, great piece (also nice pics.) I have a painfully slow '77 project that I'm just about finished with myself in need of a thermo switch...gonna give this a try (seems like vinegar is the magic solution to everything) thanks again.
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