So we had been on an ATV ride 33 miles and it was a lot of mud etc.. , atv got hot last 8 miles, we should of sprayed out the fan/radiator throughout the day and did NOT so when we got home we sprayed it all out... still would not come on so bought a new fan, still would not come on, bought a new sensor still would not come on, hot wired fan the fan does work so its not the fan itselft.. so in reading different forums we also replaced the circuit breaker..?? still can NOT get it to come on.. at whits ends anyone with anykind of help its greatly appreciated!!!!!!!!!!!!!!!!!!!!!!!!!

 

Sounds like you need to start at the beginning and pull the radiator for a good cleaning. Many people think they've cleaned them when they can still be caked with mud and dirt. Circuit breaker has to have power on each side of the red wire,recheck it. All connections must be clean and dry. Use a little electrical grease if you have it.Radiator sensor provides the ground path for the fan to kick on,but make sure the fan power wire has voltage. Front end needs to be raised with the wheels off the ground and cap off to bleed the air from the system. Squeezing hoses helps plus the fan should kick on when hot enough if the coolant is circulating properly. It may take several times for the fan to cycle on and of to get all the trapped air out of the system. As the coolant level goes down keep topping off the radiator. After it's finally bled top of the radiator,replace the cap and fill the over flow bottle. Not a fun job when playing in mud.

 

can you tell me if there would be a fuse somewhere that might need to be replaced..???
The radiator has been pulled and cleaned really good!!! there was a lot of stuff in it.. but its out.
the fan power wires have voltage checked..
ran the machine til it got hot , but fan will not kick on..??

 

There's a 10 amp fan thermal circuit breaker in a sealed pouch under the front panel. Make sure you have power on each side. If not cut the pouch open and you can get a replacement at any auto supply. If you have power then the most common problem on these was the radiator sensor. It closes it's contacts and provides the ground path for the fan. Since you've tested that the fan power wire has voltage,then that sounds like the problem. You can also double check and test the sensor by checking ohms resistance when cold and then use a heat gun or drop it in hot water and check resistance again. It should drop. If it doesn't change resistance values then the sensor has shorted and won't allow ground to the fan motor. You can use a Wells Sw526 from any auto supply for about 25 bucks.Or ebay has them also.Fan Heat Sensor Switch for Polaris Sportsman 500 HO 4x4 2004 2006 2008 | eBay Either way you go you have to cut the wires and use your old connector. Still better than paying 70 bucks for an oem sensor. Didn't see that you checked the fan motor itself. You can jump the fan to 12 volts and see if the fan is ok. If the fan is the problem,then Spal has plenty of them which is what the oem is.http://www.the-fan-man.com/shop/-c-33.html
https://webstore.spalusa.com/en-us/p...rcycleatv.aspx

 

ok so we have already done all that.. not knowing what it actually was we have replaced the Fan, and the sensor, and the circuit.. and still .. the fan does not come on.. is there anyway that the thermostat would cause this..?? I don't want to keep replacing stuff but its getting riduclious now.. we have a NEW fan, NEW sensor, NEW circuit amp and still fan will not run ....

 

"IF" you have 12 volts to the fan hot wire,but the fan won't kick on,it has to be a ground problem either from the sensor connector area or the sensor itself may be faulty even with it being new or trace the harness grounds. Only thing left that I can think of. Didn't see the part on the thermostat.. Not really if coolant is circulating properly,the radiator and hoses are warm along with the water pump housing. Test it in hot water,if it opens it's good.. You can even pull the rubber surround from the thermostat and use it alone on the thermostat housing to seal it up,bleed the system again and see if any change. Only other thing to keep water from circulating is the impeller itself or an internally stopped up radiator.