I am looking at an 01 sportsman to do some trading on. The fan sensor switch went out and they put a toggle switch on it instead. He says sometimes the hot light will come on even when the fan switch is on. Is this a glitch due to the sensor being bypassed or is it a bigger problem. There is also an issue with the needle and seat overflowing. Not a big one it itself. Any ideas if this is serious and about what is the average retail on these. Sorry it is a 500ho. Tony

 

The thing that would bother me has it been over heated since the sensor was bad, rings and so on could be damage, warpped.

 

Just put a new thermal switch in the rad. Any auto parts store will sell you one for $25. Just say you need a fan switch for a 84-88 Nissan Maxama or a 86-89 Nissan Stanza. They work just splice your old Polaris switch plug on.

Here are some that work but there are more.
BlueStreak TS-127
Napa FS147
Wells SW526

If the hot light comes on with the fan on ,then maybe the rad needs a good cleaning off of baked on mud.

Take the carb off you may need a new needle valve O ring or the floats adjusted.