This weekend in the dunes, my fu#$in fan crapped out again, anyway last time this happened the oil light would come on when the bike got to hot, well this time the oil light never came on and one time when i stopped the radiator was bubblin and fluid was comin out the vent tube, so it was boilin, hot.. Any way how can i test the circut for the oil light, i can test the bulb, it works, how can i test the circut???
Rob.

 

Hey, what size dynojet main did you tell me you are now running? 185? That might be a little lean causing you to run hot. You might try going up to 190/195. I think Hightower is running a similar setup to yours and if I remember right, he is running a 195 with his yoshi. Just a thought! I don't know about the oil sensor though, maybe someone else can help there? It was nice meeting someone else from the forum at Kermit this weekend!

Later, Steve

 

The light can come on for two reasons - lack of oil pressure, sensed by a sensor just above the filter cover on top the crankcase with two wires to it - or by a temperature sensor on the right side of the motor at the thermostat housing. There are two sensors on the thermostat housing - one for turning the fan on, with trips at 203 degrees, and one for turning the light on in the event of an overheat, which trips at 239 degrees.
If you are overheated but no light comes on, and you've put voltage to the light and it does indeed work, then the likely cause is a faulty temp switch that will need replaced. Run the bike up to opperating temperature and check the switch for voltage.

yes its true - I run a 195 Dynojet main, needle on 3rd groove, no lid on airbox, with Yoshi slip-on at sea level. even with this set-up, I experienced overheat with a red warning light and had to shut down several occasions when my fan was dead - only at slow speed riding or long periods of idling. As long as I had plenty of air flowing it was fine. I, and most people, need the fan. My fan died becaue my old RWR pipe would not clear the heat shield on the back of the fan, so I took it off. All that heat melted down the insulation on the motor windings! Others fail from vibration breaking the brush wires inside, which can be soldered back on, but take care to re-install the magnets exactly right upon re-assembly or it may run backwards!

Good luck!! Sorry to hear about the problem - it sucks when your down![img]i/expressions/face-icon-small-smile.gif[/img]

 

Just take off the wires that go to the neutral light and put them on the oil light and put it in neutral and if it comes on the oil light works, If the oil light does not come on, then obviously you need to replace it. (I had to replace my neutral light the first month of owning my ds.

 

Allright, i figured out the oil light problem one of the wires came loose, no big deal, thanks for the info guys

Hey HIGHTOWER, im building up a stack of crapped out fans in my garage, i took one apart once and im no elec engineer and i couldnt get it back together, If i am successful with soldering, which ill try again will it be tougher than new? I mounted a new fan in tonight an i squized rubber washers i cut out of an old handgrip, so that might help the vibs. What is the secret on getting the thing back together???

And for the guys who posted that LED's are the answer well i ran one out in the dunes this weekend and it did not even make it till the sun went down, when i took the light off the whole LED assembly was all apart everywhere, it like 15 pieces, do i ride harder than average or something?? Even the LED cant hold up? what to do?

Ill try runnig an 190 jet,as im running a 185 now, and see if that helps my engine heat any, i also am going to try to stick an oil cooler in there somewhere i just cant figure out where it wont block the air to the radiator.
DPGRDI

buttfungus, that was fun riding with you, well meet up sometime again, im going to be going up there alot after Xmas time cause that is when ill be buyin my wife's quad and the temps will be lower.

 

Its a tedious task - but can be done. If you get it apart and see that wires are borken of the brushes, then that's probably all that's wrong, unlike my sitation I described above.
When you're ready to re-assemble after soldering, you have to put the magnets in the way they came out. Two will have a mark on them, two won't, and they have opposing poles. I don't remember if they face each other on opposite sides, or if they are right beside each other, sorry. After putting the magnets in wrap a piece of black tape around them all to hold in place. Before putting the two halves back together, you'll have to get the brushes pulled back out of the way of the commutator that will sit between them all. Pull their springs back a little, and slide the brushes out of their hole far enough to clear, and use the spring tension to hold them that way. then assemble the two halves of the fan, but before completely pressing them together you will have to stick a tiny pair of needle nose, or a skinny screwdriver in and push the brushes down against the comututator, making sure the springs snap over them and fall into the groove right.
Sorry to hear about the LED - I've been using one for quite a while with
no issues, perhaps the one you got was like faulty or something? I want one of Smitty's tailights - he posted on your other thread, I went to his site a while back, they are sweet. He'll custom make it to say whatever you waant, max 7 letters.

 

First off, yes the magnets that have the marks go across from each other, second when you have to pull the 4 little magnets back, get some small wire (4 small wires, small in diameter not length) at the end of each make a small hook shape, put the hook on the spring and pull it back until it all the way back, then wrap the wire to the bolt holes. Do this to all 4 little magnets, slide the cover on, and simply UN wrap the wire and UN hook from the spring.
Hopefully that will make more since once you look at the fan.

As for holding the 4 big magnets, mine stayed in place for me.

 

I used fishing line to hold back the brushes while I re-assembled the two halves. The line pulls out real easy after the halves are together.
The magnets I messed up on and got wrong the first time and as Hightower said. Mine ran backwards.