Help - 2nd Fan wont Fit! (using DCP mount on 636)

[broham]

The back of my r6 fan is hitting the cam sensor on the front of the head on my 636 motor (03-04 head)

Details: Okay, so I have an 05 radiator on my 03. I'm using the DCP radiator cage that's supposed to fit the 05 radiator, but has 03 mounts. I had to drop the top frame mounts about an inch lower because the rad cage was hitting the bottom triple, but I think it is because I have a steel frame. (or maybe I was mistakenly sent a standard 05 mount from dcp) So anyway,, I ran this all last season with no problems. Texas is hot so I decided to get a second fan. I ordered a light gray r6 fan because I had the mount for it that came with my rad cage.

Turns out this 2nd fan doesn't fit. The fan motor is hitting my cam sensor.


Here the radiator is attached at the bottom, and you can see how far off the radiator is from the top mounts because it's hitting the cam sensor plug.


Here is the cam sensor's factory position.


I tried turning the cam sensor 90� at a time and found one position where the sensor wouldn't hit the fan. (The retaining clip that holds the cam sensor in place makes it impossible to rotate the sensor any less than 90� at a time) Unfortunately, it looks like this position puts these wires dangerously close to the header. what do you guys think?



If no one here can help me figure something out, I'm going to toss this fan in the trash.

[Duane S.]

I actually trimmed my sensor some but just run a longer screw on the bottom bracket to the motor..... put a nut in between so it spaces it away from that sensor since you run sf and your tire still wont hit the radiator.... oh I even trimmed the mounts on the cage part some so that the forks can turn without hitting takes a lil grinding but it works even on a ff bike

[broham]

so I set it up and if I move my bottom bracket out enough to fit everything, it's pretty close to my tire. Do you guys think this will hit when I bottom out the forks?


Duane, how did you trim your sensor?

[Duane S.]

press your forks down have someone look and see how close it gets.......another idea make your forks soft see how close it gets

[GAMstunts]

You should be able to flip that sensor 180 and still use the retaining clip.

[broham]

Originally Posted by GAMstunts

You should be able to flip that sensor 180 and still use the retaining clip.

I did and it puts my wires pretty close to my header. I posted a pic

[kirny]

Originally Posted by Duane S.

press your forks down have someone look and see how close it gets.......another idea make your forks soft see how close it gets

I understand what your saying but you should not have to change your fork settings in order to make a part fit...nor should you have to pay for something and do this much work to make it fit its bullshit