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The fan would operate sometimes and)Tj T* ( not others depending $apparently$ on the bike hitting a bump. If you)Tj T* ( don't have a wiring diagram, download a copy from Mark's site: )Tj /CS0 cs 0.255 0.286 0.345 scn 32.878 0 Td (Wiring)Tj ET /CS0 CS 0.255 0.286 0.345 SCN 0.75 w q 1 0 0 1 535.791 480 cm 0 0 m 38.643 0 l h S Q BT 12 0 0 12 141.25 464.25 Tm ( Diagram)Tj ET q 1 0 0 1 141.25 463.5 cm 0 0 m 55.441 0 l h S Q BT /CS1 cs 0 scn 12 0 0 12 196.6914 464.25 Tm (. If you print the diagram $maybe blow up the section you)Tj -4.62 -1.375 Td ( need$, you will be able to use a marker to trace over the wires as you\ )Tj T* ( check to avoid being confused.)Tj 0 -2.375 TD (Prepare to be annoyed, frustrated and confused but not necessarily in)Tj 0 -1.375 TD ( that order. Electrical is the weakest area in most technicians practice\ )Tj T* ( but shouldn't be because it is simply a matter of deduction $or maybe)Tj T* ( that should be induction! VBG$ Time, experience and practice will see)Tj T* ( your skills improve. There is nothing magic about wiring!)Tj 0 -2.375 TD (The relay circuit has two main parts, the part that controls the relay a\ nd)Tj 0 -1.375 TD ( the part that is controlled by the relay. A relay is simply a switch th\ at is)Tj T* ( operated electrically. Allowing power to flow to the electro-magnet)Tj T* ( winding will create a magnetic field that attracts the contact arm. Thi\ s is)Tj T* ( the "click" you hear when a relay operates- the relay contacts snapping\ )Tj T* ( together. When operating a switch, you perform the action that is done)Tj T* ( by the control circuit in a relay.)Tj 0 -2.375 TD (A typical Bosch type relay has 5 connections as follows:)Tj T* (1 & 2- Winding $control circuit$ has two connections, one for each "en\ d")Tj 0 -1.375 TD ( of the winding.)Tj 0 -2.375 TD (3- Contact arm $common in the switched or controlled circuit.$)Tj T* (4- Normally open contact.)Tj T* (5- Normally closed contact.)Tj ET EMC /Article <>BDC EMC /Article <>BDC EMC endstream endobj 26 0 obj <> endobj 27 0 obj (��$�1��ykǴo) endobj 30 0 obj <> endobj 31 0 obj <> endobj 32 0 obj <> endobj 82 0 obj <> endobj 81 0 obj <> endobj 80 0 obj <> endobj 28 0 obj [/ICCBased 83 0 R] endobj 29 0 obj [/ICCBased 84 0 R] endobj 84 0 obj <>stream H�b``��$��WR��~��|@��T��#��2S/`M.(*��(%�8H��8c�-�� f�ԉd�9�@6_IjH��9��(3=�D��R�1%?)U!��$5�X�3/9�� (�$5�j�%V*�'��&*��r"(,!��!�0b;�C��Ң2(��ɘ� �I�8/ endstream endobj 83 0 obj <>stream H��yTSw�oɞ��c 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The fan should operate whenever)Tj T* ( these two connectors are bridged with a wire.)Tj 0 -2.375 TD (If the fan operates with the controlled $switched$ connectors bridged,\ )Tj 0 -1.375 TD ( wiggle, prod and push all the wires you can reach to see if the fan)Tj T* ( operates or stops $depending$. If it does you will have to fiddle wit\ h the)Tj T* ( wiring to try to localize the intermittent connection. If it doesn't op\ erate,)Tj T* ( try wiggling the wires to see if it operates as you will be trying to m\ ake)Tj T* ( the bad connection open and close the circuit in order to figure out)Tj T* ( where the problem lies in the harness.)Tj 0 -2.375 TD (If this does not show up the fault, try the same thing by connecting you\ r)Tj 0 -1.375 TD ( test light across the control circuit connections in the relay plug, th\ en)Tj T* ( push prod and wiggle.)Tj 0 -2.375 TD (Another option, if you can't locate the broken wire or bad connection is\ )Tj 0 -1.375 TD ( to determine whether the power wire or fan wire $load wire$ is the on\ e)Tj T* ( that is at fault. This will be useful if the wires are run together whe\ re)Tj T* ( the fault lies since wiggling the wires will not allow you to blame one\ )Tj T* ( wire in particular.)Tj 0 -2.375 TD (In order to see which wire is at fault, first connect your test light fr\ om)Tj 0 -1.375 TD ( the powered connector $the one which comes from the battery positive)Tj T* ( through the fuse$, to a good ground and do the wiggle bit. If the ligh\ t)Tj T* ( will come on or off then this wire is at fault $or you haven't succeed\ ed in)Tj T* ( operating the bad connection$.)Tj 0 -2.375 TD (If this doesn't show the fault, connect your test light from the battery\ )Tj 0 -1.375 TD ( positive to the switched contact of the relay connector plug $the one \ to)Tj T* ( the fan$. The fan will not run because the test light has too much)Tj T* ( resistance to allow enough current flow to run the fan. On the other)Tj T* ( hand, the fan will allow ample current flow for the test light to opera\ te)Tj T* ( so it should light. Now wiggle the wires to see if the test light flick\ ers,)Tj T* ( goes off or comes on to locate the fault.)Tj 0 -2.375 TD (Similarly, if the fault could not be localized to one wire in particular\ on)Tj 0 -1.375 TD ( the control side of the circuit, you can test the wires individually by\ )Tj T* ( connecting your test light from the battery positive to the relay plug)Tj T* ( connection which goes to the temperature switch, ground the switch)Tj T* ( connector and proceed to wiggle, prod and push. 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When the relay has power applied to the magnet, "click" the)Tj T* ( contact arm's contact snaps against the normally open contact and)Tj T* ( power can flow through the circuit just like would happen if you touche\ d)Tj T* ( two wires together or flipped a switch.)Tj 0 -2.375 TD (Many relays have a normally closed contact also as I said earlier and th\ e)Tj 0 -1.375 TD ( contact arm is in contact with the normally closed contact unless power\ )Tj T* ( is applied to the relay's winding. This normally closed circuit is usef\ ul to)Tj T* ( have something turned on when power isn't flowing in a circuit such as)Tj T* ( operating low beams then using a switch to close the relay to operate)Tj T* ( high beam. If the switch fails the circuit will fail with the low beams\ on)Tj T* ( so some lights will be always available.)Tj 0 -2.375 TD (Consulting the wiring diagram will allow you to determine the wires that\ )Tj 0 -1.375 TD ( form the control and controlled $switched$ circuits to the relay. Onc\ e)Tj T* ( you know which wire is which, you can use a test light or voltmeter to)Tj T* ( see whether power is available to the switched circuit $relay connecto\ r)Tj T* ( with one lead of your test light and ground with the other$. You can)Tj T* ( easily make a test light for doing this with a small light bulb and soc\ ket.)Tj T* ( A pair of spade lug connectors on the ends of the bulb socket wires wil\ l)Tj T* ( allow you to plug into the relay plug connections for hands free.)Tj 0 -2.375 TD (You should have power to one of the control circuit connections $per th\ e)Tj 0 -1.375 TD ( wiring diagram$ and the other connection should be connected to the)Tj T* ( bike's frame $ground circuit$ when the radiator is hot enough to clos\ e)Tj T* ( the temperature switch. The ground circuit connects back to the battery\ )Tj T* ( negative to complete the path for power to the battery.)Tj 0 -2.375 TD (My bet is that you have either, a broken wire making and breaking)Tj 0 -1.375 TD ( connection inside the insulation or a loose ground connection.)Tj 0 -2.375 TD (To test for power to the control circuit connection on the relay connect\ or,)Tj 0 -1.375 TD ( remember that this circuit is hot all the time so you shouldn't have to\ )Tj T* ( have the key on. In order to check the ground connection on the relay)Tj T* ( plug, you will have to remove the plug from the temperature switch in)Tj T* ( the bottom of the radiator and connect the wire to a good ground $ a)Tj T* ( bare metal part such as a bolt$.)Tj 0 -2.375 TD (If you plug a test light into the two control circuit connections in the\ )Tj ET EMC /Article <>BDC EMC /Article <>BDC EMC endstream endobj 115 0 obj <>/BS<>/Border[0 0 0]/PA<>/Rect[13.0 729.0 130.0 766.25]/Subtype/Link/Type/Annot>> endobj 116 0 obj <>/BS<>/Border[0 0 0]/PA<>/Rect[13.0 688.0 130.0 729.0]/Subtype/Link/Type/Annot>> endobj 117 0 obj <>/BS<>/Border[0 0 0]/PA<>/Rect[13.0 664.0 130.0 688.0]/Subtype/Link/Type/Annot>> endobj 118 0 obj <>/BS<>/Border[0 0 0]/PA<>/Rect[13.0 622.0 130.0 663.0]/Subtype/Link/Type/Annot>> endobj 119 0 obj <>/BS<>/Border[0 0 0]/PA<>/Rect[13.0 598.0 130.0 622.0]/Subtype/Link/Type/Annot>> endobj 120 0 obj <>/BS<>/Border[0 0 0]/PA<>/Rect[13.0 573.0 130.0 597.0]/Subtype/Link/Type/Annot>> endobj 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