My 2002 Sportsman 500 overheated on the weekend.
I jumpered out the temp sensor in the lower rad and fan ran all the time....I added coolant and used it for the weekend and had no more overheating problems.
I changed sensor today.
I added coolant.
Ran bike with rad cap off and purged air from system....I even jumpered fan and watched coolant go down and then added a little more while it was running.
Now the fan will still not kick in.
I have 12 volts to one side of sensor(off with key switch on), and 14 volts running. But never get 14 volts on other side of sensor, so that sensor is not closing.
IF I leave the bike idling it eventually starts to heat, red light will come on dash, and it will boil coolant out of reservoir.
IF i jumper out temp sensor fan will run all the time and machine will run fine, I took it on 40 mile bike ride on the weekend and no problems.
My next step is to test the old sensor in a pot of boiling water to see if it will close.
If it was still good then is there something in my RAD? Blockage?
last resort will be to pull the new sensor and test it.
This seemed like a simple problem that is turned into a real head scratcher???
I got took for $85 dollars for a bum sensor?