I posted a while back about my '05 Outlander 400 overheating. The warning light would come on the dash, and the fan would not kick in at all. I checked the fuse and it is fine. I have a service manual and they said to insert a jumper wire where the temperature sender connector is (on the lower rad). I did this and the fan kicked in (whew, good thing). Next it said to heat some water to 185 F and check the temperature sender with a multimeter. Sender opened at 185 F, sender worked properly according to multimeter. The service manual does not offer any further advice! I went to the BRP dealer yesterday and the mechanic said if the light comes on the dash the problem is most likely the temperature sender. I bought the sender assuming this was the problem. I don't want to open the package and install this piece and risk losing $60 if this isn't the problem. [img]i/expressions/face-icon-small-confused.gif[/img]

 

I have not worked on an outy and not familiar with their electrical system, however I am quite familiar with the DS motor and I wonder if there may be some similarities so here are some things I know about the DS that are worth your looking in to:

On the DS, the red warning light does two things - it can warn of high temp, or no oil pressure. There are 3 sensors total - one that kicks on the fan, a seperate temp sensor that trips the light on if overheated, and another sensor that kicks on the light if there is no oil pressure. if the oil pressure sensor is bad, the light comes on. if the temp sensor is bad, the light comes. or if there truly is an overheat situtation, or a lack of oil pressure, of course.

since you checked fan sensor and it works and the fan is not coming on as you say, then you are likely not actually overheating.
if the temp sensor for the red light is faulty, simply disconnect it and see if the red light goes out. the temp sensor on the DS only has one wire, instead of two like the fan switch, it is the ground wire and the sensor merely completes the ground (the red light has positive power all the time).
and if the temp sensor checks out okay, the next thing is to check the oil pressure sensor, it also is a one wire grounding operation, and simply disconnecting it should make the light go out if that is the problem.

hope this helps.

 

Interesting, I'll try that right now. Thanks

 

Just reinstalled temperature sender and connector. Ran the engine for 10-15 minutes and I monitored the radiator temperature. Temp was increasing to about 165 F, then I put the cap on the rad back on. Let it idle for another 10-15 minutes. Warning light did not come on. I assume idling for 30 minutes would be sufficient to trigger the fan. Since the temp was rising in the coolant I assume the thermostat is working properly. I'm stumped!

 

Like Hightower, I don't own an Outtie either.
Here is a general thought. Most sensors don't have the current carrying capacity to run a fan. Most have relays.
Could yours have a relay? I don't know? Just a thought.

 

that is a good point Doc, worth checking too.
the DS fan switch does directly operate its fan, it has no relay. but the outy may have a larger fan, seems like my arctic cats had a relay for the fan if memory serves, the fan motor on them was much larger than the one on my DS since they had the low range gearing and made to work hard at slow speeds where not much air is coming thru the radiator.

 

i am having the same problem (sorta) while riding thru a creek, my cvt case filled with water and the engine died. Someone winched me out and i stood the bike on end to drain the water back out the rear of the cvt case. Afterwards the belt slipped bad and then the temperature light came on in the dash and it was smelling really hot. The radiator was overflowing antifreeze and the fan never kicked on. There are spare fuses in the mini tool kit that came with my outlander but i cant find a fuse for the fan. Would you happen to know if there is a fan fuse and if so, where can i find it? Thanks. Ronnie

 

Look in the front cubby, sometimes they're tucked under.
Should be 4 fuses, can't remember which one, probably one of the 20 A.
As for my problem, even though the temp sensor reacted on the ohmmeter with the heat gun, I replaced it anyways and now it works like it should! Thanks for the help guys. Monty

 

Thanks Monty. Found them right where you said they were even though they are cleverly disguised as wire connectors . I would of never figured out the fuses were inside if the connectors. The good news is a fuse was blown and now the fan works. Now on to my cluth problem.........