Long with lots of pics...

I decided to purchase and install the Wards Cooling Fan on my 2012 Limited.

I've read some other installs of the Fan and they've helped me, so I decided to document the install for others. I purchased the Fan, Thermal Switch, and the special Mount that Jason sells for my Mini Beast Horn. I also opted for the B+ connector as I've already got a few things hooked to the battery.

Shipping was fast and quality was exceptional on all parts.

I recommend removing the fuel tank as it makes for a much cleaner wiring job, and it makes it easier to remove the Horn bracket.

After removing the tank, I removed the upper half of the plastic wire loom channel. I then drilled a 1/2" hole thru the plastic at the outer edge directly over where the Horn bracket goes. It worked out really well, the plastic "juts out" a little right where I needed to drill, couldn't have planned it better if I would've tried








Hooked up the B+ adapter, attached the negative ring terminal to the battery post, ran the wire thru the trough and dropped it down through the hole I had drilled.

With the tank removed, it's easy to remove the horn bracket.

As far as getting the old rubber bushing off of the horn bracket, I went for the easy way, I just cut the stud on the back of the bracket and drilled it out. Worked out great, the bushing just popped off. I had read from Jason and other installs, about trying to get the bushing off and trying to save the pressed fit nut in the bracket. I was just planning on using a locknut on the stud anyway, so I didn't care about trying to save the press fit nut. Jason included a locknut so I didn't need to rummage for one.














Re-attached the horn bracket, installed the upper half of the wire loom trough, and reinstalled the tank.

Here is where I ran into a little trouble. I installed the Thermal switch as per Jason's instructions, (wires oriented on top of each other, thin side between the fins, and tapped in with a thin piece of wood).

The switch went in tight, but seemed to go in ok. I thought all was good until I went to wire the thermal switch to the power lead and popped the fuse. Pulled the switch back out and I could see where the Mylar covering had come off which caused a short.





Not really sure what I did wrong, but Jason is sending me a new switch. Even though it isn't required, I got some of this for next time.



I don't think the RTV Gasket is needed to hold in the switch, but I'm hoping it provides somewhat of a lubricant to protect the Mylar sleeve, we'll see.

I think Jason should include a small tube of this with the kit, but that's his decision.


Mounted the Fan and bushing




I needed to space my Mini Beast out about 1/4" so the bracket would clear the fan housing. I wanted as much "surface area" as possible, so I used 4- 5/16" X 1 1/4" Stainless Steel Fender Washers.





Mounted the Mini Beast, added a 5/16" X 1 1/2" Chrome Fender Washer, and the original Chrome Cap Nut. Worked out perfect, left about 7/16" of threads left for the nut.



Here's what it looks like




Like I said, very happy with Jason's kit, and I appreciate him sending me a replacement Thermal Switch, although, not really sure what went wrong. Hopefully the RTV Gasket material will help it to slide in a little easier next time.

I can't believe the power these fans have. I direct wired them without the switch just to test them, and holy crap! It's weird cause they start out slow and then build speed. They're not that loud, but they remind me of two small jet engines when they're at full speed.

I have full confidence that they will help keep the bike cool.

 

Nice write up. Thanks.
I read where the fans decrease temps by ten degrees. Is that actually all the fans reduce the temps by?

 

nice writeup Talldog.. thanks man!

 

I forgot to include a pic of the B+ connector.

I highly recommend going with this option if you have a newer Touring model, it doesn't cost extra and it makes the install easier because you don't have to get at the battery.

I decided to run the Negative terminal to the battery, but that's easier to get at, because it's not covered up like the Positive post is.

The connector is under the seat, forward of the battery.

 

super job on the write up. Let us know about the difference and if you feel it?

 

I've often thought of creating a mount that attaches to the frame and comes down to where the horn would mount.
Just never liked the idea of expensive electronics jiggling with the vibration of the heads. Thought solid mounted to the frame would be better.

Just never got around to it.

lp

 

Will do


Interesting idea, not sure how it could attach to the frame though.

I'll let ya know next summer

You're welcome!

 

Dumb question here.

What are the steps for removing the fuel tank on EFI models?

I've removed many tanks off of carbed models but I'm hesitant about doing my EFI bike.

I also noticed a "jack" on your LH side heat shield. Is this for heated clothing?

I've also been considering the Wards Cooling Fans
and appreciate your pics.

 

Maybe in a cool climate. Mine was reduced by 30 degrees.

 

Thanks for a great write-up. I will be adding the fan in the not-so-distant future, and your write-up will help.