I was searching around for a how-to guide for a fan switch for the 06 model but I couldn't find anything specific, so I decided to make one myself.
This switch setup lets you dictate when the fan comes on (switch position ON), or leave it up to the bike as per normal via thermostat reading (switch position OFF).
Sorry for quality of pics - taken with my Blackberry. You can click on the thumbnail to enlarge.
1. Take off your left side fairing
(I'll assume you know how to so this, so no pics)
2. Next to the fusebox you'll find a box containing a selection of relays.
Remove the rubber sleeve from the box.
3. Press in the brown clips and pull out the brown plastic casing
You want the left hand relay in this picture, which is the fan relay.
4. Flip the case over to reveal the wires.
The only wire you'll want is the grey-blue
wire, which provides ground to the relay, as highlighted.
5. Wire up your switch.
This is the switch I bought (DPST rocker type switch) which meets my criteria: low mass profile, able to see which side is on, and locking nut on the reverse end.
This is how I wired up the switch. Soldered two wires - one to ground the switch (end post) and one to go to the relay (middle post, same row). Then covered solders with heatshrink and insulation tape, and heatshrink on the whole end of the switch so provide some protection from the elements. This picture shows my practice run with wiring...actually I had to buy a new switch because I stuffed this one up.
6. Choose a mounting point.
I chose to mount in the case where the exhaust valve servo lives, by the lock to release the rear seat. I had to relocate the servo to directly under the rear seat, but am gonna get the servo eliminator soon so this is temporary.
To remove the casing you need to remove the annoying screw thingee here:
And a nut here:
Then just remove the locking cable from the bracket that holds the rear seat on:
I used the locking nut from the switch to mark out the hole I needed to drill...you'll note that it's off-center with the lock but the casing slopes just after half way down and I wanted a flush fit for the switch.
As you can see I drilled heaps of little holes as I didnt have a drill bit big enough, and I filed them out to make one big hole.
7. Run the wires and reassemble the servo case
I ran the wires through the same hole the locking cable goes through, then grounded the ground wire to the frame and ran the "relay" wire under the gas tank to the relay.
I stripped the end of the wire, tinned it, and shoved it into the same socket that the grey-blue wire goes into.
8. Test, reassemble fairings, then done
Here is where i put the servo (temporarily under the rear seat, by the left hand vent thing)
And this is the finished result:
I can easily reach for and flip the switch while riding. If you have any questions please let me know