Hey guys,

Hopefully someone can give me some info on what i screwed upon my 2004 Polaris 400 sportsman.

A few weeks ago i dunked my bike head first into a bog and it went in to the rear tires. We towed the bike back home, de thawed and cleaned it, changed the motor oil 8 times, diff fluids,tran. Since that ride my fan was very noisy and my HOT indicator would come on. This was where all my troubles have begun!

I had a bad bearing in my fan, so instead of paying 400 from the dealer i modified a fan from the junkyard to fit in. I wired the fan with the original plug and plugged it in. I purchased and installed the sensor located on the side of the motor (120 bux).

After haveing these modifications done to my bike, I ran the bike with the rad cap off so i could make sure it was burped, the bike overheated and the HOT indicator came on again and the fan didn't.

So we were planing a run out last night and since I was having overheating issues i decided to hardwire the fan. When i first connected the wires to the fan I did the backwards and the fan was spinning the wrong direction, so I reversed the wires for proper direction and accidently plugged the plug into where the fan is supposed to be plugged in.(I was using stripless wire connectors)
So in doin this i had no power when i turned the key forward, I then realized i had the fan plugged in. I disconnected the plug and got power to the POD again. I noticed the fan wasn't spinning fast so i thought maybe the battery needed a little boost.
I tried starting the bike and it wouldn't start, just kept turning over and over, but when i gave up and let off the key it would catch and the bike would run.
I turned the bike off and waited a min and the same thing would happen again when i tried to start it, even with the choke or no choke, giving it gas or no gas. It would just catch when i gave up.

After the third try the bike had no power at all. The POD was dead, no headlights, nothing. We tested power and we got folowing some of the leads to some relays. The battery has lots of power.

This is where i'm at right now, i'm goin to take it to the dealer but i'd rather fix the problem myself. Hopefully some of you can give me some insight of what to check or what happened to my bike.

thanks for any info you can give.

Jack

 

not sure but maybe you overloaded relays and burnt them out? if you had air inthe system that would cause the bike to overheat and make the light to come on. will the bike start w/ the pull start?

 

no, i tried pull starting and won't run.

 

You can buy a replacement fan , go on e-bay and type in spal- fans , then find the correct fan, sounds like you fried the ecm or something. Fan is around $100 bucks.

 

the fan i modified to fit in works quite well. I found a replacement fan from universalpartsinc for 150 shipped to canada(going to order it when i get this mess sorted out). I dropped my bike off to the dealer this mornin and waiting to hear the results.

 

let us know what they say

 

absolutely

 

I got my atv back from the dealer today. The ECM is bad and the reason why my fan won't work. An open circuit in the wireing(broken wire) is why the bike stopped working. They fixed the wire and replaced the ECM for 1.5 hours labour.