Well I know its only been a year since this post but my buddy finally broke down and took his wheeler into the dealer for the overheating issue as its been sitting ever since.

It was the fuse that is sealed inside that black plastic bag, I guess there notorius for that......Runs like a top now..............

 

Glad to see you got it fixed...Thanks for the update...

John

 

alot of times when we drive our bikes through mud and water over time we do not realize that that all that stuff gets into places and helps cause little issues such as bad conections and corrsion that may have lead to the bad fuse. glad they found the issue for sure.

 

Indeed true, I have just recently been going through an issue related to water in the recoil housing... Totally my own fault for not simply pulling the drain plug after riding in mud/water.

Lesson learned and I will be paying much better attention in the future.

 

The same part went out on mine. I was going to suggest it to ya. But you said you checked the fan. On mine the blown fuse was not allowing the fan to run. Was that what was causing yours to overheat?

 

The wheeler is actually a buddy of mines and I was trying to troubleshoot and or fix the problem for him, but I dont remember exactly the whole scenario its been awhile. I remember jumping the fan to see if it worked which it did. I would have to go back and re-read my threads/posts on it to be sure about the fan. But it does make sense because maybe that fuse was not allowing the fan to kick on and off at the correct times....

I dont know how to link my other threads on this matter to this post. So do a search for exact phrase:
2005 sportsman 700 efi and
05 sportsman 700 overheating??? and this will tell you exactly what we all troublshooted and or replaced and so forth

 

Ya. I don't think it let's the fan run at all. On my service ticket. They called it a circuit breaker. I couldn't find the thing when I was troubleshooting.

 

I always just caused them a thermal fuse as when if too much of a load or they got hot they would trip until they cooled down,then they would reset,plus they get corrosion after a period of time and fail. I've split a bunch of sealed pouches only to find circuit breakers all eat up. You would think in a shrink wrap cover they would last! Part of it I guess is electrical corrosion from the different metals just as a battery corrodes,plus if any water gets in. Plus I had the most trouble with the 10 am breakers,not so much with the 20 amp ones. OPT

 

Well all I know is his machine was constantly overheating and we tried troubleshooting and replacing everything and to still to no avail........he took it in to a dealer finally and all they replaced was that fuse/circuit breaker in that sealed bag and now it runs top no more overheating.........................

 

I have an 04 sportsman 700 twin and it bubbles coolant out the resivore bottle when it warms up any helpful hints ?