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Old October 31st, 2020, 06:52 PM   #1
Badapplesrepair
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Name: Carlos
Location: Hollywood FL
Join Date: Aug 2020

Motorcycle(s): 2008 Ninja 250

Posts: 15
2009 Fan Switch

I have a 2009 250, radiator needed replacement. Found for $50 a brand new aluminum radiator that claimed to be a direct fit. I got everything installed and it looks like a direct replacement but when it was time to install the fan switch it was two sizes too big. My question is what do I need to find a compatible replacement, I’ve been looking for some sort of data sheet on the oem part to see if I can find something similar but I haven’t found what I’m looking for. Does anybody know this information or where I can find it?
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Old November 1st, 2020, 10:05 AM   #2
DannoXYZ
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Can you post photo of your thermoswitch next to hole in radiator? Checking with vendor you bought radiator from might be easiest. Ask them if they have thermoswitch that'll fit.

Otherwise, you'll need to measure actual thread-size of hole in radiator.

1. Measure ID of hole with calipers.

2. Measure thread-spacing with thread pitch gauge


Now, once you've got measurements, there are two kinds of thermoswitch threads:

Metric thermoswitch is what bike originally came with. These tend to be 16 or 18mm with O-ring and sealed connector. If the 1st thread and deeper threads you measured are same diameter, hole in radiator is metric. Add about 1mm to your measurements to find thread-diameter of switch.

SAE/NPT threads are tapered. You can determine by measuring 1st thread having larger diameter than deeper ones. These typically come in 1/4", 3/8", 1/2" NPT tapered threads. Use teflon plumbing tape to seal when installing.

Match up specs you measured with one of readily available sensors. If it's SAE/NPT, you'll have to chop off harness-connector and solder on 1/4" female-spade connectors. Or make adapter harness.

Last futzed with by DannoXYZ; November 1st, 2020 at 01:03 PM.
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