I have a 95 Polaris explorer 4x4 2 stroke, love it but not sure the fan is coming on, questioning if radiator sensor is bad, no real way to unplug from the radiator I've found or from the fan motor (otherwise I would jump it straight to bypass radiator sensor). The only option I'm thinking is trial and error on the 4 wires that go into the fan motor. Any ideas?

 

Fan sensors were the main problem on the older models since they were at the top of the radiator. If coolant ever got below the sensor they could short out. Just unplug the sensor from the fan motor,jump the red/white and brown(ground) wire at the fan to a battery and check that the fan works.If it does then another bad sensor. Problem is that these are NLA from Polaris,just used ones on ebay.Polaris Xplorer Scrambler Radiator Thermostat Fan Sensor Switch 4110178 95 | eBay The newer style ones on ebay,Amazon with the short leads may not fit the radiator opening.Best to try to match up the size at an auto store and make your own spade connections. Here's an example.

 

So maybe it's a weird question but why is there 4 wires coming out from the fan?

 

Should be a red wire that supplies power to the radiator sensor. The other sensor wire is red/white. When the sensor close it complete the circuit, jumps voltage from the sensor red/white that goes to the fan motor.Brown is tied into a group of brown ground wires. This is what's showing directly off the schematic.What color wires are you talking about? This may be what's confusing you as the sensor wires branch off also.Updated replacement motors have a hot wire and brown ground wire.

 

There is a red wire looks like going to the radiator (just discovered) grouped with a red or brown wire (kinda faded hard to distinguish color) there are 2 more wires going to the fan but not sure yet what colors without peeling off the protective sheathing, don't think those other 2 wires have any real significance though. Just the red and brown are of importance right?

 

Like I mentioned the fan sensor wires tie into other wires and it can look like a wasp nest. Main this is one wire has to have power at the radiator sensor.Usually the red according to the schematic. The other wire is powered up once the sensor gets hot and completes the circuit.It's the one that powers up the fan motor. Colors to the fan motor itself may change to red and brown at its termination. Screwy set up on this.

 

Traced everything down and it's the fan motor not running. Can I replace it with a universal fan and what size will fit?

 

You can either replace just the motor that's replaces your #4170009 motor.New Polaris Sport 400L ATV Radiator Cooling Fan Motor,4170009,70-1001,RFM0001 | eBay OR you can replace the whole assy with this one that's supposed to interchange with the old one.High Performance Polaris Radiator Cooling Fan Magnum Sportsman Scrambler 400 NEW | eBay

 

Have you had much success in rebuilding these motors?

 

Zero,we chunked em right into the trash can...