I have a 2004 sportsman that I'm having overheating issues. I know the fan worked earlier this year but recently I've had the overheating light come on and the fan will is not running. I've ran current to the fan and it works. I've tested the circuit breaker it shows continuity so I believe it is good. I am guessing the sensor in the radiator is ok because it tells the computer the engine is hot. The radiator is full. Is there a fuse or something else that I'm missing. The dealer said the sensor could be bad but I do not want to spend $60. if I don't have to. Help please!

Also, does anyone know where to get an electronic manual cheap. I'm sure that would help.

Thanks,

 

Jump the Fan's two wire leads with a 12 DC source to make sure the fan is not the problem first step.

If its Your Themal Switch (Part number 4010161) you can get there three from a Auto store for less money.

Napa FS147
Wells SW526
BlueStreak TS-127

All have the same Screw thread (M16x1.5). I have been using the Blue Streak but know guys using the Napa as well.

 

TLC I did verify the fan runs jumping it off the battery. Is there a resistance reading to test the thermal switch?

 

The only thing My Manual (Clymer) only says about the Themal switch, is its kick on the and off temp rating.
The Auto store sensor can be more then $15- $20, I would give it a try. I only paid $35 and thats Canadain pricing.
When you refill the System with coolant do forget to burb the airs out of the system.

 

I'm making sure the thermal switch is the one located in the lower right corner of the radiator?

 

Thats her. With the Auto store switch you will have to cut of there connection end and use your old Polaris switch connector end in its place.

 

Ok, Here is what I found. The exhaust gasket from the manifold was leaking. Some how the engine thought it was overheating or maybe it was because the exhaust was heating up the radiator?? Anyhow I replaced the gasket and while I was checking the fan it started working. It cycles on and off like is suppose to and the engine is not overheating. Might be good to keep in mind. Thanks for all the help!