[Redhawk]

Redhawk here, and also being a redneck, I made a probably not so smart modification on account of my cooling fan not coming on when it should or at all. After the extent of my knowledge and abilities of making sure the fuse was ok, I didn't want to pay the dealer to fix it so I hooked it to a toggle switch from the "out" side of the 15 amp fuse. The following may sound stupid and I am pretty sure it is: The fan will turn in both directions depending on how it is connected. I have it pulling air through the oil cooler and the radiator which would seem to me to be the way it is supposed to run. And it is running wide open but I have the ability to turn it on or off at any time. Can anyone shoot holes in this?

[NMKawierider]

The fans assist in the moving of air through the oil cooler and radiator as if you were moving forward so yes, you have it turning in the correct direction. The only hole I will shoot is....having the system work automatically is preferred because of two reasons. 1- every time you forget to turn it on, it will overheat before you remember and the overall temperature will not stay as consistent or within a small range. This is hard on these and most any engine. And 2- these fan motors are not designed to run all the time or as a continuous-duty motor and as such will wear out quite quickly...and probably when you are many miles from the truck leaving you with no options.

9 out of 10 CFM fan problems are the thermo switch...and that's on the radiator. An easy fix if that's the case. Even if it was the relay, still worth fixing the system. Nothing wrong with having a backup plan or bypass ready to go..hell I have one just in case. But might consider fixing the problem and keeping all systems complete and functioning. Just my thoughts. 

[REDRIDER]

I would do what NMK says, The only other issue I see is that you said you wired it outside the fuse? I am assuming that means you have no fuse on the CKT, this is always bad it will take you all of 5 minutes to put a fuse in the ckt and $5. Do it melting wires and fires are no fun. Especially on the fan ckt it pulls a decent amount of amps and if it gets clogged with mud or stuck it will pull enough amps to melt shit down.

[Redhawk]

Thanks for the replies. I do want to fix it correctly. NMK could you post a picture of the switch. I could not find anything on or near the radiator. It is fused, 15 amp, the way I hooked it up, but I would like it back the way it is supposed to be. The thermal switch sounds like the first thing to change out. If you could post a pic., I believe I could do that. I may need further assistance if this is not the problem.

[NMKawierider]

Thanks for the replies. I do want to fix it correctly. NMK could you post a picture of the switch. I could not find anything on or near the radiator. It is fused, 15 amp, the way I hooked it up, but I would like it back the way it is supposed to be. The thermal switch sounds like the first thing to change out. If you could post a pic., I believe I could do that. I may need further assistance if this is not the problem.

I'll get a pic next time I'm out in the shop but its on the passenger side of the radiator about 3/4 of the way up. Its the only thing on the radiator with wires going to it. Most of is install our by-pass on those wires. They just need jumpered together to activate the fan relay.

[Redhawk]

That's how I got home on my Polaris. I found it and connected the wires. Fan ran constantly, but I made it out of the woods on it. I will have to look better on the CFM. Thanks.

[chuddly]

The best and easiest way to do a fan bypass like what you are talking about it tap into the wires before and after the thermo switch on the radiator (dont cut them just tap into them) and put one of each to a switch.  Doesnt matter what one goes where.  When they pass through (when you turn the switch on) it is exactly the same as the machine saying it needs the fan on because of its temp.  Its all done via grounds and there is no power to run or mess with.  Best thing about this way is if you have the switch off its all still automatic like it was from the factory or if the switch were to fail.  I run this way because I wan my fan on ALL THE TIME when im racing mine.  I found it helps it stay cooler instead of letting the thermo switch kick it off and on.

[Badgoat]

Just replaced mine.  It's on the passenger side 3/4 up the radiator.

[Redhawk]

I located it, behind the light bucket where it should be (LOL)! Don't get me wrong, I am not a die hard Polaris fan, I like my CFM Z Force, but theirs is at the bottom right hand corner of the radiator in full sight and easy access. Also not to disparage CFM, but I do believe that switch has to be below the coolant line to actually work, being just slightly low of coolant where it is located may be the problem in some of the seemingly way to many cases of thermo switch failure. I do not know how much it costs. I am about to find out. I do know anti-freeze is rediculously exspensive and it is going to be a problem getting to it. I think I will reconnect everything back to factory wiring specs and let it run parked and see if the fan will kick in once it reaches the temp for that switch to activate. It may have been low on coolant. It did seem like I added more water than what coolant came out of the overflow now that I think about it. Thank you everyone for your help, wheelers are the best.

[Badgoat]

Try Alpha Sports, cost of the thermal switch was about $33 with shipping and I got it in under 3 days.

[Redhawk]

Thanks for the pix. The dealer here has one a little cheaper.

[Badgoat]

The part was only $25 and 8 for priority shipping.  My dealer was back ordered and didn't know when  the were getting more.   

[NMKawierider]

The part was only $25 and 8 for priority shipping.  My dealer was back ordered and didn't know when  the were getting more.   

That's ridiculous...this is the #1 part these need...they should have a box full on hand at all times.

[Redhawk]

My dealership wants $18 plus tax and has one (probably a box full) in stock. I asked if they had an issue with them going out and he said, "yea we have changed a few". So multiply his few by about a factor of ten. But the price ain't bad.

[NMKawierider]

My dealership wants $18 plus tax and has one (probably a box full) in stock. I asked if they had an issue with them going out and he said, "yea we have changed a few". So multiply his few by about a factor of ten. But the price ain't bad.

Yeah that is a good price.