my fan only kicks on in the hottest of conditions, how have you made out with this issue?

 

I opened up the rubber boots under the front panel and found one of the leads on the thermal fuses to be corroded so I cleaned it as best I could and then put some dielectric grease on the connections before taping it back up.

Even though the thermal switch for the fan was providing 12+ volts at the connection for the fan when the coolant was really warm, the fan wouldn't kick on until the coolant was "hot". Not really sure why the 12+ volts (when it was only warm) wouldn't have been enough to start up the fan.

I tired to burp the air out of the coolant system by slightly revving the engine to get good flow going thru and kept the Rad. cap off until the coolant was really warm.

I've ridden it a few times without is spooging out the overflow tank and so far so good. The coolant level has dropped slightly but I suspect that was due to more trapped air in the system.

I read in a Polaris Shop Manual that the Rad. cap is supposed to be rated for 13 psi but haven't changed it out yet. The stock cap that came on the machine (from the factory) is stamped either 09 or 60 depending on which way you look at it so I'm not sure how that equates.

I've been carrying a small bottle of coolant with and will continue to do so until I'm confident it won't spooge but with the problem being so sporadic I'll probably be carrying it forever.

As always, any helpful suggestions would be appreciated.
Effer

 

Is this seal OK? ATV Time :: View topic - Water Pump Mechanical Seal how to replace - 2001 Sportsman

 

Is there anyway to check the integrity of that seal without tearing it apart?
Is there a weep hole that would indicate it leaking?

 

The water pump does have a weap hole to tell you if its bad.