I have a 2004 Sportsman 700 which has been over heating. I bought this used and have had it a couple of weeks. When looking into the issue the wires connected to the sensor on the radiator and the block (near the thermostat) were disconnected. I noticed a hole in the radiator, so I replaced the radiator and hooked up the wires for the sensors. The senser that goes to the radiator had a jumper in the clip, so the fan would run all the time. Now, after conecting the wires to the sensers, the fan wont turn on. Would the cause be a bad senser on the block? I already ordered a new thermostat (because of a bad gasket).

Steve

 

It sounds to me that the thermal sensor is bad. I had to replace mine a few weeks back. The fan would run constantly when jumped but otherwise it would not come on. Also, after that repair I had an issue with a leak out the radiator cap. Apparently the plastic filler neck swelled and did not allow the cap to seal properly. I had to replace the filler neck and put a new radiator cap on as well.