Rock killed my radiator fan

TownsendsFJR1300

2007 FZ6
Site Supporter
Looking again at my bike, it appears you could remove the plastic radiator cover and perhaps pop rivit (or drill and bolt on) on an extension of plastic, thin galvanized sheet metal, etc from the cover back towards the header (not touching the radiator) but extending just beyond the fan blades.

That would prevent any crap from getting stuck up there, wouldn't transfer heat. As for the plastic, obviously black is preferred and a large piece wouldn't be necessary. It may have to be notched if you have a lower mounting bolt to get around it..


Just to confirm, the 06 radiator is set farther back from the radiator than the 07 and up bikes?
 

elus1ve

Member
Anyone knows if the FZ6R Radiator fan is similar to the FZ6? I have found a pretty good deal for a 2009 FZ6R fan.

This is what I have found:
  • FZ6 of 2007 to 2009 uses: Yamaha 4S8-12405-00-00 BLOWER ASSY
  • Some 2009 FZ6 and FZ6R 2009&above uses: Yamaha 20S-12405-00-00 BLOWER ASSY

Picture-wise they are similar. They both have three mounting points.

Googling failures on the FZ6R Radiator fan results in much less hits than the FZ6. There is a long history of FZ6 (2007-2009) with the radiator fan problem (check this post in this forum: http://www.600riders.com/forum/fz6-mods/6289-different-radiator-fan-design.html). Has there been a change in the design of the 2009 fan?
 

FinalImpact

2 Da Street, Knobs R Gone
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This is interesting; a Denso sponsored sight that doesn't list blower fans, blower motors, heater motors, cooling fans, but it does list everything else you can think of.

Can you peal the label off the motor and look for any other stamps or details that could be used to cross reference it to a valid part number?

http://www.densoaftermarket.com/catalog/
 

elus1ve

Member
I have put the fan back on the bike now. Won't be examining the fan in details until I replace it with a new one. Will let you know even though I don't think there is anything else behind the label.

Denso is a part supplier to Yamaha. As such I don't think they need to advertise their products on their website. They won't even sell those parts to consumers, that should be part of a contract that Denso and Yamaha have together.

Further Googling into compatible radiator fans, I believe that the FZ6R fans and FZ6 (2007 and up) fans are the same. If someone can confirm that would be great.

It also seems that the R6 motor and blades are the same, but the mounting positions are not the same. The mount could be easily swapped I believe. Connector wise they look the same.
 

elus1ve

Member
I got a replacement fan for $40 !!! :cheer: Hooray! Went to a scrap and apparently a crashed Kawasaki had the exact same motor, with a slightly different spare part no. The mounting were different but I simply mounted with my existing one. The blades were more or less the same but I also switched it with my previous one. Connector was also different but it was simply a matter of switch the pins. Tested it and it works fine! Seems to be slightly louder but not sure.

Changing the fan though was a b!tch! You have to remove the air intake, the battery, the battery box and the connector is hidden underneath a pile of cables. It really couldn't have been at more impractical spot. In the second pic, the connector is the one in the middle of the pic. Very well hidden. And damn that bike was dirty in there. Clean it all up before closing.

Take care of your fans ppl, it is a lot of trouble to change it.

Finalimpact: There are no other labels on the fan itself.
The fan is sealed, cannot pry open. Tried roughly but bended the metal instead.
Motogiro: Do you still want the motor?
 
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Motogiro

Vrrroooooom!
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I got a replacement fan for $40 !!! :cheer: Hooray! Went to a scrap and apparently a crashed Kawasaki had the exact same motor, with a slightly different spare part no. The mounting were different but I simply mounted with my existing one. The blades were more or less the same but I also switched it with my previous one. Tested it and it works fine! Seems to be slightly louder but not sure.

Changing the fan though was a b!tch! You have to remove the air intake, the battery, the battery box and the connector is hidden underneath a pile of cables. It really couldn't have been at more impractical spot.

Take care of your fans ppl, it is a lot of trouble to change it.

Finalimpact: There are no other labels on the fan itself.
The fan is sealed, cannot pry open. Tried roughly but bended the metal instead.
Motogiro: Do you still want the motor?
Good catch on the cheapo Kawi fan!

Yes I'd like to try to see if I can repair it and hopefully if successful I could do a step by step thread on the repair. Hopefully It's a micro-temp type fuse that blows and I can replace it. I'll PM you my snail mail. :)
 

mas172

Junior Member
FZ6 2009 picked up a stone on my way to port dover Friday the 13th and blew a fan fuse ,replaced fuse and the fan still did not work.I removed the fan at home and got it to work again.The motor will come apart by using a screwdriver to start it opening at a spot that looks like a drain hole then keep prying open bit by bit inserting shims or coins to hold it open as the magnetic force will try to pull it shut(must remove brackets first). I found o brush was seized in so I pulled the brush out and removed the spring being careful not to break the wire off the brush.I then cleaned out the slot the brush slides into so the brush moves easy.Clean every thing up and make sure armature is not warped.To reinstall armature put cardbord over brushes to hold down then pull it out as it gets close to going back together
 

Motogiro

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FZ6 2009 picked up a stone on my way to port dover Friday the 13th and blew a fan fuse ,replaced fuse and the fan still did not work.I removed the fan at home and got it to work again.The motor will come apart by using a screwdriver to start it opening at a spot that looks like a drain hole then keep prying open bit by bit inserting shims or coins to hold it open as the magnetic force will try to pull it shut(must remove brackets first). I found o brush was seized in so I pulled the brush out and removed the spring being careful not to break the wire off the brush.I then cleaned out the slot the brush slides into so the brush moves easy.Clean every thing up and make sure armature is not warped.To reinstall armature put cardbord over brushes to hold down then pull it out as it gets close to going back together

That's great! That's what I was wanting to try when I got a bad fan to see if it was serviceable. I was thinking of doing a post with pictures to share so that other members could do the same if I was successful. I wonder if the brush spring overheats and looses temper when the fan jams?

Did you take any pictures?
 

mas172

Junior Member
the spring seems ok.The brush slot seems to tightend around the brush so I used a mini screwdriver to scrape the inside to make clearance.
 

FinalImpact

2 Da Street, Knobs R Gone
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the spring seems ok.The brush slot seems to tightend around the brush so I used a mini screwdriver to scrape the inside to make clearance.
^^AWESOME! ^^
So does it seem to run like normal under test?

Good job and I must say that is the strangest DC motor layout I've seen!
 

FinalImpact

2 Da Street, Knobs R Gone
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Looks like picture # 4 shows where the brushes make contact with the commutator and the other side (next picture) shows where the windings have a little temperature change from being stuck and heated (high current and no rotation).





 

FinalImpact

2 Da Street, Knobs R Gone
Super Moderator
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Sorry more posts by me - so was your motor "locked" or did it still spin by hand?

And one thing I have noticed about brushes is once a DC motor stalls and all the current is dumped into the carbon brush it does 2 things: 1) brush gets brittle and may chip easier 2) because its harder now after being heated it wears the copper faster than it would have before being heated.


This is what we wanted to see so we could find out if repairs could be made!

Again, I thank you for taking to the time to show us the guts! You mind if I jack your pictures into an album?
 

TownsendsFJR1300

2007 FZ6
Site Supporter
I have it saved from post 28 and back for future use.. :) The fan pictured is from an 2007 MODEL.

From what Mas172 states, it sounds like the brushes, with the extra heat (generated from jambing up with 12 volts still going to it) had the brushes "weld" themselves to the brush housings. Does that sound about right Cliff/Final, ?

No one to my knowledge has had one apart until now.


BTW, Excellent job (and smart) getting that motor apart without destroying it!
 
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Motogiro

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I have it saved from post 28 and back for future use.. :)

Maybe the moderator for this section of the forum could transfer this thread to the FZ6 Electrical section and we could 'sticky' this thread!

This is very valuable info for an expensive item/repair. This seems to occur often I believe on the earlier 06 and earlier fans because of rocks. :)
 

mas172

Junior Member
in rotation it would jam in one spot.I have ran it without the fan on and it spins ok,also check for warpage.I have ordered a new one.Only 3 left in USA none in Canada,back order until September
 

elus1ve

Member
Hey amazing job mas172 :thumbup:

I hope you didn't get to pay the full price for a new one. North of $200 is too much for a fan imo and yes, almost no shop have them in store.

Btw, my fan that broke turns freely. Doesn't look like the same symptoms.

In any case, it will be in the mail to Motogiro tomorrow.
 
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