Incredible!…RUclips comes through again for my ATV fix! Four components that could have failed fan motor, temp sensor in radiator, an electrical relay, and finally this circuit breaker. I tested the first three and found them to be working, but the your video led me to this failed circuit breaker. Yay! Thanks so much! I saw this component prior to the video, but I would not have guessed that it was part of this cooling fan circuitry.
Im an electrician, a fan motor, draws more amps, starting and stopping, and its harder on the fan, its called locked rotor amp draw, so unless im missing something its better to have the fan run, when the key is on, good video, thanks
Greetings from Western Canada! Excellent tutorial! We'll done! Thank you! Cheers and a Merry Christmas and a happy new year 2024! Safe riding to all! 👍
This is my exact unit. Replaces the relay, breaker, and radiator temp sensor but haven’t tried bridging the cable that plugs into the radiator temp sensor to test it. I wonder if I got a new one that is faulty because the fan only seems to turn on every 10 minutes or so and the tach continues to flash HOT. Then today I got no fan at all. Tested the fan and it works fine. Tomorrow I will bridge the connector that plugs into the radiator temp sensor and test the relay base plug with a multimeter to check on my circuit breaker. Will report back. Thanks very much.
The fan kicking on about every 10 minutes or so sounds normal with the machine idling. Are you sure your engine is actually getting hot? Be sure your coolant level is full so the temperature switch in the radiator is working properly. You can get an infrared thermometer cheap at Harbor Freight or Amazon to check the engine and radiator temperature. Also check all electrical connections including fuses. Corrosion and dirt are common on these machines so take apart all connections to be sure they’re clean and add dielectric grease. Pull the fuses and check them too. My speedometer wasn’t working and it turned out to be corrosion on the fuse. I tested it with a test light with the fuse in place and it checked out fine but the connection was bad.
@suttonmotorsportsgarage5301 Great trouble shooting video! And great content. I’m currently troubleshooting my 2017 Polaris Sportsman 570. I’m a bit confused about some of your video…When trouble shooting the radiator temperature switch you used a jumper wire and turned the key on and you said if the fan turns on then it’s not the radiator temperature switch. Then later on when trouble shooting the 10A breaker, you replaced the 10A breaker and then you went back to the radiator temperature switch and said if the fan comes on then you fixed the problem. After replacing the breaker, shouldn’t you have went back to the relay and checked for 2 positive and 2 ground on the relay?
When I jumped the temperature switch, the fan didn’t work so I assumed there was a problem somewhere else. After I replaced the breaker, I jumped the switch again and the fan worked so I know the relay and the rest of the circuit is working properly. In the following video I ran the engine and waited for the fan to kick on and off so I know the switch is working properly. These machines change from year to year so your components may be a little different. I hope this helps and good luck!
@@suttonmotorsportsgarage5301 that's a good question. I will be testing the sensor next. Dropping it in a pot of hot water and testing resistance. I ended up with this 2002 Sportsman 700 on trade I tore down built it back up going to sell it. No history on it. It will look nice when I'm finished but even then with rebuilt OEM carburetor, new bushings, rubber odds-and-ends new rear drive shaft and axles. New tie rod ends. A bunch of odds and ends it still we'll have a pretty low resale value. But I got basically just thrown in with the trade. Radiator flushed new fuel pump diaphragm fuel filter fluids changed a bunch of little odds and ends even the seat will have a new foam and be covered professionally by me. I did all the work myself so not too bad pretty fun
Mine was pretty much the same. I have a few things left to address, but it runs good now. I think I’ll keep it though. It’s fun to ride and it’s useful around the yard too.
I’ve noticed different year machines have different set ups. You should have a temp switch somewhere. If not on the radiator, it could be on the engine, unless yours is controlled by the computer since it is an efi machine.
What year is this. I’m having problems trouble shooting my Polaris 700 sportsman 2005. I’ve replaced water pump, thermostat, and on to the fan. Thanks for the video
I was only getting about 7.5 volts to the fan. Found my circuit breaker completely corroded, but when I bypassed that I am still only getting 7.5 volts to blower. Any ideas? Both blades going to the relay are getting 12 volts.
Check all other connections including fuses and grounds. Dirt and corrosion could cause resistance. My speedometer wasn’t working because the fuse connection was dirty, even though the fuse was good. After that, start checking for continuity at different points in the circuit. You may need a wiring diagram for that. You should be able to find one online. I’m assuming you’re bypassing the temperature switch when you’re getting the 7.5 volt reading? You can test the switch for continuity too when the temperature is high enough for the fan to run. I hope this helps.
@@suttonmotorsportsgarage5301 I'm a little embarrassed. At some point I clamped my multi-meter ground to the bolt on top of the front shock. Turns out, that's not a good ground with all the rubber isolation going to that member. When I used a good ground, and buy passed the temp sensor I am now getting 12V to the fan. I suspect my temp switch was bad. Now about the only thing I haven't replaced is the temp sensor that screws into the the side of the engine. Can you explain how to test that component? For example, if I unplug that alone will it drive the fan to spin? Or is that sensor only for the hot temp alarm on the gauge? Thank!
One thing I am really struggling with is that I cant get the reverse override to work. I tested the yellow button with a meter and it works fine but nothing. Also swapped the tach with one from a 4 wheeler that has working revers over ride and it still didn’t work. What else could be causing it not to work? I also can’t swap through all the tach settings with the yellow button. The little arrow won’t move and I have no fuel gauge reading. Even with the known working tach I didn’t get any of it either. All of those issues started on the same day about two years ago.
It sounds like you may have a wiring issue. I found a repair manual online with a schematic diagram. You’ll have to start checking circuits including wires, connections and components. Good luck and let me know what you find.
This is a very good video and should have many more views and likes. I have this problem on a 2004 trail boss 330 except when I bypass the thermostat sensor, the fan does not come on. The fan comes on when directly connected to the battery. However, the wires from the fan run through the ECM . The fan actually worked correctly before the Stator went out. I replaced the Stator and the atv started right up, however the fan no longer comes on. I wonder if the ECM went bad when the Stator went bad?or do you know of any fuses that would blow before it affected the ECM? I cannot find any , though I found something by the seat in a plastic sealed pouch. It does not look exactly like yours but it looks like it could have fuses in it. Thanks for any advice. Could I just run the fan from the battery and bypass the ECM? Or would that be a problem to run the fan full time?
@@edenmenastrees7226 Another video asked the same question about bypassing the thermal sensor and just running the fan direct and the guy said he would not recommend as it would drawn down the battery. I have a 2004 polaris magnum 4x4 and previous owner wired the fan direct, probably because the temp sensor went bad, resulting in the fan not working. Anyway, he wired the fan direct so when you turn on the key, the fan constantly runs and because of that, the battery on mine would draw down quickly. I am in process of testing the old temp sensor in the machine, and then would buy a new one, if the old one is bad. I'm assuming it's bad....
If you are riding at a speed high enough to get sufficient air flow through the radiator it probably will not come on. At slow speeds or idling without moving it should come on when the engine reaches the upper end of the normal operating temperature. It should run for about 5-10 minutes and then shut off. Keep an eye out for a “HOT” message on the digital readout. The fan should kick on before you get to that point. If it doesn’t, you have a problem with the fan or fan circuit. I have another video on this where you can see the fan kick on and off while idling to get an idea of the timing of the fan.
I have a 2001 Sportsman 500 HO, I can't find a fuse panel anywhere. I jumped the fan and it works. I replaced the thermostat and the temperature switch in the radiator. I can't find the fuses or relay any info is appreciated
I’m not familiar with that year. I did a little searching around and a lot of people have the same problem. Someone said there is a fuse box under the seat near the battery. Someone else said they don’t have fuses. They have in line breakers. Did you locate the breaker that went bad on mine and test it?
The breaker is in a plastic pouch tied up to the wire loom top left under the front cover. Cut the bag open and replace the breaker with a BR20 from any auto parts store
@@MrBeats_6000 I will check that, honestly its been parked and not used for months now I had given up until I can take it in for repair. But thank you I will check that
Other than a possible draw on the battery/ charging system and wearing out a fan now and then. Some people carry a jumper wire in case of a bad switch so it’s at least a good temporary fix.
It seems that the older machines don’t have fuses. Mine is a 2009. From what I could find, there are a couple of circuit breakers in a waterproof pouch in the wiring harness and a fusible link which I believe is coming off the positive side of the battery. I hope this helps you out.
Incredible!…RUclips comes through again for my ATV fix!
Four components that could have failed fan motor, temp sensor in radiator, an electrical relay, and finally this circuit breaker. I tested the first three and found them to be working, but the your video led me to this failed circuit breaker. Yay! Thanks so much!
I saw this component prior to the video, but I would not have guessed that it was part of this cooling fan circuitry.
I’m glad it helped you! Thank you for watching.
That is a good video and should definitely help someone with the same problem. Great content keep it up!
Thanks, will do!
Im an electrician, a fan motor, draws more amps, starting and stopping, and its harder on the fan, its called locked rotor amp draw, so unless im missing something its better to have the fan run, when the key is on, good video, thanks
Greetings from Western Canada! Excellent tutorial! We'll done! Thank you! Cheers and a Merry Christmas and a happy new year 2024! Safe riding to all! 👍
Thank you very much! Merry Christmas and happy New Year to you too!
This is my exact unit. Replaces the relay, breaker, and radiator temp sensor but haven’t tried bridging the cable that plugs into the radiator temp sensor to test it. I wonder if I got a new one that is faulty because the fan only seems to turn on every 10 minutes or so and the tach continues to flash HOT. Then today I got no fan at all. Tested the fan and it works fine. Tomorrow I will bridge the connector that plugs into the radiator temp sensor and test the relay base plug with a multimeter to check on my circuit breaker. Will report back. Thanks very much.
The fan kicking on about every 10 minutes or so sounds normal with the machine idling. Are you sure your engine is actually getting hot? Be sure your coolant level is full so the temperature switch in the radiator is working properly. You can get an infrared thermometer cheap at Harbor Freight or Amazon to check the engine and radiator temperature. Also check all electrical connections including fuses. Corrosion and dirt are common on these machines so take apart all connections to be sure they’re clean and add dielectric grease. Pull the fuses and check them too. My speedometer wasn’t working and it turned out to be corrosion on the fuse. I tested it with a test light with the fuse in place and it checked out fine but the connection was bad.
@suttonmotorsportsgarage5301
Great trouble shooting video! And great content. I’m currently troubleshooting my 2017 Polaris Sportsman 570. I’m a bit confused about some of your video…When trouble shooting the radiator temperature switch you used a jumper wire and turned the key on and you said if the fan turns on then it’s not the radiator temperature switch. Then later on when trouble shooting the 10A breaker, you replaced the 10A breaker and then you went back to the radiator temperature switch and said if the fan comes on then you fixed the problem. After replacing the breaker, shouldn’t you have went back to the relay and checked for 2 positive and 2 ground on the relay?
When I jumped the temperature switch, the fan didn’t work so I assumed there was a problem somewhere else. After I replaced the breaker, I jumped the switch again and the fan worked so I know the relay and the rest of the circuit is working properly. In the following video I ran the engine and waited for the fan to kick on and off so I know the switch is working properly. These machines change from year to year so your components may be a little different. I hope this helps and good luck!
Thanks. They had it hardwired. I removed the hardwire. Bypassed the sensor and it came right on
Was it hard wired because the sensor was bad?
@@suttonmotorsportsgarage5301 that's a good question. I will be testing the sensor next. Dropping it in a pot of hot water and testing resistance. I ended up with this 2002 Sportsman 700 on trade I tore down built it back up going to sell it. No history on it. It will look nice when I'm finished but even then with rebuilt OEM carburetor, new bushings, rubber odds-and-ends new rear drive shaft and axles. New tie rod ends. A bunch of odds and ends it still we'll have a pretty low resale value. But I got basically just thrown in with the trade. Radiator flushed new fuel pump diaphragm fuel filter fluids changed a bunch of little odds and ends even the seat will have a new foam and be covered professionally by me. I did all the work myself so not too bad pretty fun
Mine was pretty much the same. I have a few things left to address, but it runs good now. I think I’ll keep it though. It’s fun to ride and it’s useful around the yard too.
Great video!
Thanks. I hope it was helpful.
I own a sportsman 2006 500 efi and it does not have a that temp switch is somewhere else or is it a deferent system?
I’ve noticed different year machines have different set ups. You should have a temp switch somewhere. If not on the radiator, it could be on the engine, unless yours is controlled by the computer since it is an efi machine.
@@suttonmotorsportsgarage5301thanks
What year is this. I’m having problems trouble shooting my Polaris 700 sportsman 2005. I’ve replaced water pump, thermostat, and on to the fan. Thanks for the video
It’s a 2009 500 HO. You should be able to hear the fan kicking on. Mine is pretty loud.
The system should be basically the same. Some of the components may be in different locations.
The title says Sportsman 500 but the parts bag says 550? Are they the same part?
Thanks for pointing that out. I didn’t notice that before! As long as yours looks like that and is a 10 amp breaker it should be the same part.
I was only getting about 7.5 volts to the fan. Found my circuit breaker completely corroded, but when I bypassed that I am still only getting 7.5 volts to blower. Any ideas? Both blades going to the relay are getting 12 volts.
Check all other connections including fuses and grounds. Dirt and corrosion could cause resistance. My speedometer wasn’t working because the fuse connection was dirty, even though the fuse was good. After that, start checking for continuity at different points in the circuit. You may need a wiring diagram for that. You should be able to find one online. I’m assuming you’re bypassing the temperature switch when you’re getting the 7.5 volt reading? You can test the switch for continuity too when the temperature is high enough for the fan to run. I hope this helps.
@@suttonmotorsportsgarage5301 I'm a little embarrassed. At some point I clamped my multi-meter ground to the bolt on top of the front shock. Turns out, that's not a good ground with all the rubber isolation going to that member. When I used a good ground, and buy passed the temp sensor I am now getting 12V to the fan. I suspect my temp switch was bad. Now about the only thing I haven't replaced is the temp sensor that screws into the the side of the engine. Can you explain how to test that component? For example, if I unplug that alone will it drive the fan to spin? Or is that sensor only for the hot temp alarm on the gauge? Thank!
One thing I am really struggling with is that I cant get the reverse override to work. I tested the yellow button with a meter and it works fine but nothing. Also swapped the tach with one from a 4 wheeler that has working revers over ride and it still didn’t work. What else could be causing it not to work? I also can’t swap through all the tach settings with the yellow button. The little arrow won’t move and I have no fuel gauge reading. Even with the known working tach I didn’t get any of it either. All of those issues started on the same day about two years ago.
It sounds like you may have a wiring issue. I found a repair manual online with a schematic diagram. You’ll have to start checking circuits including wires, connections and components. Good luck and let me know what you find.
This is a very good video and should have many more views and likes. I have this problem on a 2004 trail boss 330 except when I bypass the thermostat sensor, the fan does not come on. The fan comes on when directly connected to the battery. However, the wires from the fan run through the ECM . The fan actually worked correctly before the Stator went out. I replaced the Stator and the atv started right up, however the fan no longer comes on. I wonder if the ECM went bad when the Stator went bad?or do you know of any fuses that would blow before it affected the ECM? I cannot find any , though I found something by the seat in a plastic sealed pouch. It does not look exactly like yours but it looks like it could have fuses in it. Thanks for any advice. Could I just run the fan from the battery and bypass the ECM? Or would that be a problem to run the fan full time?
@@edenmenastrees7226 Another video asked the same question about bypassing the thermal sensor and just running the fan direct and the guy said he would not recommend as it would drawn down the battery. I have a 2004 polaris magnum 4x4 and previous owner wired the fan direct, probably because the temp sensor went bad, resulting in the fan not working. Anyway, he wired the fan direct so when you turn on the key, the fan constantly runs and because of that, the battery on mine would draw down quickly.
I am in process of testing the old temp sensor in the machine, and then would buy a new one, if the old one is bad. I'm assuming it's bad....
Very well done! Only thing is you should never use your fingers to measure continuity as we are a conductor!
I never really considered that.
the video was made 8mos ago. Question for you hows the fan 8mos later. it sounded like it was struggling
The fan works fine, but it’s kind of loud. I was thinking of replacing it thinking that the bearing may be going bad.
I have a 2008. Have not had it very long. Took it for short ride, felt engine warm up and never heard fan cut on. At what point should it run?
If you are riding at a speed high enough to get sufficient air flow through the radiator it probably will not come on. At slow speeds or idling without moving it should come on when the engine reaches the upper end of the normal operating temperature. It should run for about 5-10 minutes and then shut off. Keep an eye out for a “HOT” message on the digital readout. The fan should kick on before you get to that point. If it doesn’t, you have a problem with the fan or fan circuit. I have another video on this where you can see the fan kick on and off while idling to get an idea of the timing of the fan.
Thank you.
I have a 2001 Sportsman 500 HO, I can't find a fuse panel anywhere. I jumped the fan and it works. I replaced the thermostat and the temperature switch in the radiator. I can't find the fuses or relay any info is appreciated
I’m not familiar with that year. I did a little searching around and a lot of people have the same problem. Someone said there is a fuse box under the seat near the battery. Someone else said they don’t have fuses. They have in line breakers. Did you locate the breaker that went bad on mine and test it?
The breaker is in a plastic pouch tied up to the wire loom top left under the front cover. Cut the bag open and replace the breaker with a BR20 from any auto parts store
@@MrBeats_6000 I will check that, honestly its been parked and not used for months now I had given up until I can take it in for repair. But thank you I will check that
Seems it would be safer to have the fan run all the time , am i wrong, ?
Other than a possible draw on the battery/ charging system and wearing out a fan now and then. Some people carry a jumper wire in case of a bad switch so it’s at least a good temporary fix.
What size nut goes onto the bolt that goes thru the fan
I’m not sure. I haven’t taken my fan apart. Sorry
Should fan always come on when i turn key on?
Only if the engine is at or above normal operating temperature
I Dint have fuses, at least not where those are. I've looked and looked and can't find fuses. Mine is 2001. Does anyone have any ideas?
It seems that the older machines don’t have fuses. Mine is a 2009. From what I could find, there are a couple of circuit breakers in a waterproof pouch in the wiring harness and a fusible link which I believe is coming off the positive side of the battery. I hope this helps you out.
What year is this atv?
2009 Sportsman 500HO
En français
Maybe google can translate it?