Thermo Fan Switch Fix

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Cakey
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Thermo Fan Switch Fix

#1

Post by Cakey »

Don't know if this will help anyone but I have been playing around fixing some stuff whilst waiting for parts for my engine rebuild.

It's just a continue on from the thermo fan fix in the shop talk section and I can only trial it in the saucepan until the bike gets back together anyway but thought I would post.

I had three switches

1 broke in half
1 would not work at all when testing
1 stayed on all the time

So I took too the one that would not turn on at all.

1. Use a screw driver around the top edge where the edge is pressed in
2. Turned upside down in the vise and turned to release the two prongs and base from the housing
3. Prised it up to seperate
4. Soaked everything in vinegar and cleaned with a scrubbing brush
5.blew out with the air compressor
6. Cleaned the contact points with some 600 paper
7. Turned upside down in the vise and clamped in
8. Sealed the edge with high temp loctite gasket sealer
9. Taped it back into place
10. Pressed the edge back down tapping with a hammer
11. Put the base back on
12. Tested in the the saucepan
13. It worked
14. Came on about 60 but did not turn off
15. Took the pin out and filed it down with a file. It turned on and off.
16. I tapped the back on to tight so I could have pulled back up again but instead I filed their which adjusted the turn on temp. Just filed it until when I screwed on the base the continuity meter showed that there was no contact.

I am going to try another one and see if I can make it work better.
Attachments
Screw driver on edge
Screw driver on edge
image.jpg (54.2 KiB) Viewed 541 times
Screw pins in vice and twist
Screw pins in vice and twist
image.jpg (51.01 KiB) Viewed 541 times
Lever up. Inside is clean cause I took photo after cleaning
Lever up. Inside is clean cause I took photo after cleaning
image.jpg (48.6 KiB) Viewed 541 times
Inside dirty
Inside dirty
image.jpg (31.69 KiB) Viewed 541 times
Inside dirty
Inside dirty
image.jpg (28.93 KiB) Viewed 541 times
1975 Gl1000
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Cakey
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Location: Darwin Australia

Re: Thermo Fan Switch Fix

#2

Post by Cakey »

Some more procedures
Attachments
Parts
Parts
image.jpg (30.28 KiB) Viewed 540 times
Undid the bottom bit and removed the pin
Undid the bottom bit and removed the pin
image.jpg (40.23 KiB) Viewed 540 times
Soaked the parts in vinegar
Soaked the parts in vinegar
image.jpg (22.55 KiB) Viewed 540 times
Cleaned parts with toothbrush
Cleaned parts with toothbrush
image.jpg (36.6 KiB) Viewed 540 times
1975 Gl1000
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Cakey
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Re: Thermo Fan Switch Fix

#3

Post by Cakey »

More stuff
Attachments
Cleaned contacts with 600
Cleaned contacts with 600
image.jpg (53.03 KiB) Viewed 536 times
Put loctite around the edge
Put loctite around the edge
image.jpg (59.7 KiB) Viewed 536 times
Taped down
Taped down
image.jpg (58.67 KiB) Viewed 536 times
Taped the sides down again
Taped the sides down again
image.jpg (50.33 KiB) Viewed 536 times
Loctite
Loctite
image.jpg (54.41 KiB) Viewed 536 times
1975 Gl1000
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Cakey
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Re: Thermo Fan Switch Fix

#4

Post by Cakey »

Forgot to say I tested the contacts before glueing back together
Attachments
No contact
No contact
image.jpg (49.46 KiB) Viewed 535 times
Contacts pressed together
Contacts pressed together
image.jpg (50.34 KiB) Viewed 535 times
1975 Gl1000
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Cakey
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Re: Thermo Fan Switch Fix

#5

Post by Cakey »

I reckon it's got potential. I cannot test it in the bike yet but kick it around and see if. It's worth a cracker

How far you tap the top back in determines a lot so I reckon connect the meter up to the pins whilst knocking it back on to get it closer.

All the best

anim-cheers1
Attachments
Cleaned up the edges
Cleaned up the edges
image.jpg (32.91 KiB) Viewed 534 times
Cold water no contact
Cold water no contact
image.jpg (49.05 KiB) Viewed 534 times
Turning on at 63
Turning on at 63
image.jpg (57.27 KiB) Viewed 534 times
Turning off at 65
Turning off at 65
image.jpg (55.72 KiB) Viewed 534 times
1975 Gl1000
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pierce
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Re: Thermo Fan Switch Fix

#6

Post by pierce »

You are a man after my own heart.

I did something similar, but you went deeper than I did. I pulled the small sensor and made sure the small pin was clear, cleaned the outside, boiled and assembled. Worked fine after that.

Great pictures and write up as well.
1976 GL1000
1978 Gl1000
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Cakey
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Re: Thermo Fan Switch Fix

#7

Post by Cakey »

Cheers Pierce,

I have another one that I am going to play with to see if I can do it better. I had three of the switches and the taking off the end and soaking in the vinegar got one working but it stays on all the time and the other one I could not get it to turn on at all. The one that did not turn on at all is the one I did in this thread. I am going to try the other one and see if I can get it working again to (top turn off). A mate at work has some clear 3M epoxy that goes to 140 Celcius so I might try that.

I don't know how long it will fix the problem as I said it is untried on the bike. Someone else might improve on it or do a better job hopefully.

There is also a small plastic type tab that goes over the top of the contact and I think next time I might loctite it down so that I do not risk it moving when inserting the contacts back into the housing. I have read that when they stop working that they tend to stay on and I can see why that happens. When you move the contacts up and down they tend to stick in the closed position when dirty so a good clean out helps.

My concern was wether the loctite would hold it in postition and for how long. From the construction of the unit it appears to be blocked at the tail or pin end so water should not be able to get through so I am assuming that water will not get through to the contacts. But they always say that one should never assume :)
1975 Gl1000
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