aluminum radiator fan blades discontinued

[Mike Huber]

I've pretty much given up on the aluminun blade fans anyway...The first one I had broke a blade off....The second one was like yours and became detached from the collar.....I didn't have any JB Weld at the time so I took it iff and beat the collar back down with a hammer.... It lasted long enough fo me to order a 500 Ninja 8 bladed fan and motor for $30 shipped from Pinwall Cycle off E-bay....I just swapped the blade and I have a spare motor if I need one....I blows more air through the radiator and the splined collar is a better designed than the aluminum or stock fans. Mike Huber Carlsbad, NM To: DSN_KLR650@yahoogroups.com From: rysburnr@... Date: Thu, 11 Aug 2011 14:23:51 +0000 Subject: [DSN_KLR650] Aluminum Radiator Fan Blades Discontinued Some time ago I purchased an aluminum fan blade and installed it on my 2006 KLR650. Recently while riding the bike home from work I noticed an occasional metal-to-metal sound. I discovered the fan blade became detached where it meets the collar (the part that contains the set screw). This enabled the blades to spin freely, not when the fan motor engaged. Performing a web search I found the makers of aluminum fan blades have discontinued this product. Knowing that Fred Hink is a frequent contributor to the DSN_KLR650 listserve I contacted him for his verification and advice. Fred verified suppliers have discontinued making the fan blades, and advised using JB Weld, confirming my course of repair. I purchased the JB Weld, mixed it up according to directions, and using a disposable epoxy brush, applied the mixture to the space where the collar joins the blades. I then applied the remaining mixture to the collar and onto each blade. Using the epoxy brush allowed an even and smooth application of JB Weld. After allowing 24 hrs to dry, I secured the fan blade to the motor shaft with the set screw on the collar, applied Loctite blue to the threads at the end of the motor shaft, then secured the nut/washer to the end of the motor shaft. I detached the wire that goes to the temperature sending unit and grounded it against the cylinder head. The fan blade spun as it should, albeit very slowly. I loosened the nut slightly until the fan spun faster. All seems to be working as it should. Taking this opportunity to publically thank Fred for his help not only with this problem but also for his contributions to the DSN-KLR650 listserve. Randy Kuklis 2006 KLR650 / 2003 GL1800 / 1994 Yamaha GTS / 1987 BMW K75 MSF-Certified Instructor Stayin' Safe Motorcycle Training Senior Instructor [Non-text portions of this message have been removed]

[Rick B]

When I got home from work my shims had arrived (Thanks Fred) and so I completed the valve adjustment. The valve clearance worked came out fine, I used the shim clac program to do the figuring. The bike has 25,0000 miles on it so I had no expection that it would suddenly become a cafe racer but I do think it runs noticeably smoother and I feel that it's much more trip ready than when I started. And I learned alot about the bike and that's a big help too. Along with the valve job and the Doohickey I replaced the glass fuses with solid state added a lighter plug to blow up my air mattress, and I covered the 1" holes I drilled in the top of the aircleaqner box. I also by passed my petcock diaphragm, which I might reverse and lowered my main tank strainer. It's all been good trip prep. And a big Thanks to everybody who contributed input on this project. Have fun, Rick

[Michael Martin]

Rick, Congratulations on getting all this work done. I still wonder about your statement about having to go on reserve at 125 miles. My bike goes twice that far before I have to switch to reserve. I wonder if your bike has the stock jets in its carb. Also, what did your valve clearance measurement show before you changed the shims. Were they much tighter than spec? Mike Martin, Louisville, KY ________________________________ From: Rick B When I got home from work my shims had arrived (Thanks Fred) and so I completed the valve adjustment. The valve clearance worked came out fine, I used the shim clac program to do the figuring. The bike has 25,0000 miles on it so I had no expection that it would suddenly become a cafe racer but I do think it runs noticeably smoother and I feel that it's much more trip ready than when I started. [Non-text portions of this message have been removed]