Hey everyone,

I have unique issue with my sportsman 500, that I can't seem to find information on online. My 2000 Sportsman 500 seems to keep burning up cooling fans. I bought the quad used and the very first fan was caked in mud, so no surprise there. but I put in a brand new fan (aftermarket) and it worked for the first ride, but then melted. And this fan was clean when we took it out to see what happened.
y
So I wrote this off as a junky fan and bought different one, same thing. So finally, I bought an OEM fan, and to keep myself from wasting money on fans, I had someone help me make an intermediary wire between the fan and the quad. This way,the fuse will blow instead of ruining another fan. And as expected, the fuse is blowing. We currently have 7amp fuse in it.

Has anyone seen this sort of thing before? All of the other electrical stUff seems to be working fine (all wheel drive, headlights, etc). I am wondering if maybe the sensor which allows current to the fan is bad, and sending too much voltage?

Thanks in advance!

 

check the voltage with a meter to rule out too much power. I think it would be more like a 15 amp fuse for the fan.

 

Hey, thank you for the response. I was able to find a service manual for a 2003 Sportsman, and the manual is saying anything beyond 6.5 amps should warrant a fan replacement. I won't be able to do testing until the weekend, so I will post more about my findings when I have a chance.

Thank you