Hello all, I need to install a fan off switch, Im going to do it this week when I check on the valve ajustments. How do I cut into the wire for the fan wire.
Blew 2 fuses today
Thanks
01' 500 Cat

 

While u have the plastic off u will find a disconnect about 6" from the fan, cut 1 wire on the battery side of this plug, run wires from each
of the cut ends ( best if u solder the connections) wrap well with tape & run both wires
up to handle bars. (make sure routing allows for
steering slack) hook up to switch. (I used an
on/off switch from an 80 cc quad / very compact,
handy location, makes a neat installation.)
# 18 wire will work but # 16 is better.
I hope this helps. Good luck & good riding.

 

Look at the wire coming out of the fan, about 2-3 inches up you will see a 2 prong plug. The parts store will have plugs just like it. Mine had them with a plug on each end, that is what you need. With this all you need to cut is one of the wires connecting the plugs that you bought and there is no need to cut the harnass on the bike. I mounted my switch in the gear indicator pod on the flat portion facing the gas cap, you will need to put it torwads the left because the ignition switch is a inch or 2 long behind it also. Bottom line if you get the right plug you will not need to cut the factory harnass.