Guys, just did this conversion on my wifes 2006 Gen 1 ZX went pretty well total crap instructions though.
Pulled both side fairings, removed ALL radiator attachment bolts (3 of them) this allowed much more access and movement to get the fan in place.
Installed as high as possible and as far to the right side of the radiator as possible, pushing the attachment zip ties through the radiator was a bit spooky, LOL but it went very easily and I only got 3 of the 4 on there as it would have been a bear to get my big hands over to the last one and I am pretty persistent.
I installed the fan with the wiring pointed in the direction ofn the factory fan and used a power tap over by the factory fan plug in to get 12v+ and then found a nearby bolt to attach my 12v- ground to, carefully inspect and attach yur wires so they wont get hit with the factory fan as it really has no housing.
Double and triple check all of your bolts and wiring an test everything before you put bit all back together I tested my fan switch with no ecu and it worked perfectly.
I also added a secondary fan switch which I got from smartmoto.com (no affiliation) this plugs right into the factory harness with NO cutting or splicing it still allows all of the factory fan on/off times yet with the flip of the switch BOTH fans start blasting the heat away, it is an awesome kit for less than $40 bucks shipped from Greece in just a few days.
MY last cooling improvement is that I sent my ECU to Nels at 2wheeldynoworks to give me the flash and also have the fans come on at a lower temperature.
I have not got it back yet as I just sent it yesterday but he flashed my 2nd Gen and it is AWESOME with 206hp at the wheel.
Hope this is helpful to someone to prevent the sensation of an overheating 1st gen ZX.
Cheers.

* Last updated by: johnnyquick on 5/29/2020 @ 6:47 AM *

What fan did you use? OEM or another brand?

Mad

hey, I tried going to the smartmoto site. I just get a header with no information or menu page at all.
Same thing with Explorer and Firefox.

Mad

Fan was from Schnitz racing as in the title,
sorry www.smartmoto-electronics.com
My ecu will be back on Monday ad will try all of this out together, I like the smartmoto switch so well I am ordering one for mt gen 2 bike as well it has a nice little blue led with it so you don't forget it is on too.
Cheers brothers

I'm thinking of rapping the exhaust header pipes with fibreglass heat insulation to keep the heat of the radiator. Can anyone tell me if they have done this and was it worth the effort, or will it cause some kind of damage to the header pipes ?

Wrap is like roof tile. I've seen wrap where if say you got caught in the rain,it grabs the water, like pulling your trousers out,grab the garden hose, start spraying. And for what it's worth, the theory is that the cooling off leaves condensation between wrap and pipe, and this is how you thin the pipe out letting the rust grow.

Yeah, I wrapped. Dropped the bottom end, felt fat smoother, but would not do it again just for that grunt loss. Wrap is more for top end work. You keep the heat moving out the pipe.

Here at long gone cycles, we closed our doors. We thought we were going to make a killing specializing in overheating radiators and head gaskets blowing; we were going to make our wallets glowing... now knowing better.

Signed,
NOLTT (no overheating loser take that) to the bank.

Did I read that right?

I have also installed a second radiator fan (ZG1400 concours), flashed the ECU (cooling fans kick in at 90degC), added water wetters to coolant, but riding slowly in town the fans kick in and stay running untill I hit the open road again.
Do you think this is normal after all I have done to keep the temp down, and will wrapping the headers help at all?

* Last updated by: Yackou on 6/9/2020 @ 5:00 PM *

You're good to go. Personally, I'm more looking at 14 years worth of non-wrapped bikes and no overheating problems, no fairings melting, no rider complaints, knowing you are obviously sitting over a heatsink. I'd pass and keep the weight off. You wouldn't believe how heavy that wrap gets, pipe after pipe.

I have a 2008 that I added a 2nd fan to with the zippy things that go thru the radiator. It is a 7 in fan that is wired to the factory fan so they go on and off at the same time. The bike does not run any cooler because the fans turn on at the factory heat settings but it does cool down quicker. It has a full Leo Vince system that sits pretty close to the 2nd fan so every now and then I take a look to see if the plastic fan is melting. So far no problem and I also carry extra fuses just in case but have not had to use them.