[bwzforce800]

NMKawierider/Clark , the thermo switch has a rubber o ring on it , do you recommend I put some teflon tape on threads also or no ? My 2nd thermo switch went Saturday about 30 miles from cabin we were staying at..  I had a jumper wire with me so I was able get back. I want wire a bypass , I'll just need a basic 2 terminal ON/OFF toggle switch and 18 or 22 g wire correct ? Just quick connect to the 2 switch wires and run to the toggle switch?

Yep..all the thermoswitch does is jumper the two together so any switch that does that will do it. I have a write-up in the How To section on how I did mine. On the threads..no..I wouldn't. They aren't a tapered pipe-type thread so it won't really do anything.

So..that's two yours went through? If it does it again replace the fan relay. Some have found that the relay coil on some are pulling too many milliamps (ma) and that causes the thermoswitch to be over loaded and toast itself.   

Yea my z800 is a 2016. I had the 1st one go around 400 miles. This one went at 2270 miles. I have the Pennsylvania Cfmoto Facebook page and my machine is the one that has always had that knock sound and the rocker arm assembly recently came apart but the new rocker arm assembly didnt fix the knock I've always had so I just run it lol.

[bwzforce800]

I replaced the thermo switch and wired the bypass . Just used a simple 2 terminal ON/OFF toggle and works like it should.

[SWVProffitt]

It's most likely the thermoswitch, they are prone to failure. Fire it up and let it come to temp, about 4 bars on display. If fan doesn't engaged it's the thermoswitch. You can jump it by connecting the two wires, until you can get a replacement.
I suggest a thermoswitch from a Honda, accord, civic ect
They are better quality and will not ruin your day on the trails

Search isnt working well for me, but ive seen suggestions for a 84-85 Nissan and now the hondas.  Is there a part number for one that would be direct fit?