[NMKawierider]

Passenger side about 3"s below the upper hose.

This thread saved me A&% on the trail yesterday. My '05 ZForce 800EX temp shot all the way up. I stopped immediately and noticed the fan wasn't running. Thankfully I had cell phone signal. A quick google search led me here. Got a piece of wire off a guy on the trail, jumped the Thermoswitch connector and my fan was on again. I was thankfully able to drive it back home.  THANKS GUYS!!

You are welcome. Glad we could help. Because this does happen often, I went a head and put in a bypass switch so if it does happen..or I just need some extra wind through the radiator and oil cooler, I just hit a switch. It's in the How Tos.

[st468]

So glad this thread helped you!  I keep a paperclip bent into a "U" in my glovebox just in case for this very same issue, even though my issue ended up being the relay.  I suspect there is a possibility that my issue was caused by my use of a plug-in heated seat cover during the fall hunting season.  Perhaps it was just too much for the electrical system?  I have had no other electrical issues since though, and I now have over 500 (very enjoyable) miles on the machine. Now that it's the warm season again, I expect to hit 1000 miles by fall when my warranty expires.

[Revolutionary]

I ordered a set of temp switches for our 800's, was going to have the dealer put them in for me today. Found out that they don't fit, CF Moto changed them on the 2016's, they're a totally different sensor, size & looks wise. Seems that CF Moto knew about the problem & addressed it, this is good by them totally.

[NMKawierider]

I ordered a set of temp switches for our 800's, was going to have the dealer put them in for me today. Found out that they don't fit, CF Moto changed them on the 2016's, they're a totally different sensor, size & looks wise. Seems that CF Moto knew about the problem & addressed it, this is good by them totally.

That's good to know. I think if mine ever goes I found a Polaris sensor that will wire-in easy enough. Just need to check the thread size

[Struens]

I ordered a set of temp switches for our 800's, was going to have the dealer put them in for me today. Found out that they don't fit, CF Moto changed them on the 2016's, they're a totally different sensor, size & looks wise. Seems that CF Moto knew about the problem & addressed it, this is good by them totally.

  Thanks for sharing.  This is good to know!

[Bobbed06]

I ordered a set of temp switches for our 800's, was going to have the dealer put them in for me today. Found out that they don't fit, CF Moto changed them on the 2016's, they're a totally different sensor, size & looks wise. Seems that CF Moto knew about the problem & addressed it, this is good by them totally.

One less issue for the new owners to worry about!

In the past, when I manually control fan operation on my powersports vehicles. I have had great luck finding brass pipe plugs to remove the sensor altogether. Commonly found at any hardware store.

[Tuke]

Just wanted to say thanks to all for making repairs and troubleshooting my ute a whole lot easier. Went to go watch a rock crawling event and was driving ute and noticed that temp was rising. Fan never came on. Decided not to continue riding it and headed home. Looked at it today after reading this thread and found that thermo switch is bad. Already ordered replacement. Hope it gets here before weekend to be able to ride. But again, thanks for info.

[Karmis]

Well, it seems the 2016 have issue as well. My fan quit working while I was on a ride, 4 hours from camp. Of course it was at night also.
I simply unplugged the power supply directly to the radiator and wired in a bypass. In a few days I'll start trying to find the problem.
Behind the glove box there are 3 relays. Anyone know which one it is?

[NMKawierider]

Well, it seems the 2016 have issue as well. My fan quit working while I was on a ride, 4 hours from camp. Of course it was at night also.
I simply unplugged the power supply directly to the radiator and wired in a bypass. In a few days I'll start trying to find the problem.
Behind the glove box there are 3 relays. Anyone know which one it is?

If you bypassed the switch at the radiator, and the fan runs, that switch has failed... like so many others. Just race it.

[Zforce800]

Well, it seems the 2016 have issue as well. My fan quit working while I was on a ride, 4 hours from camp. Of course it was at night also.
I simply unplugged the power supply directly to the radiator and wired in a bypass. In a few days I'll start trying to find the problem.
Behind the glove box there are 3 relays. Anyone know which one it is?

        ,               

[Zforce800]

OK, I typed in my last post but it didn't take. Anyway, if you bypassed the switch at the radiator and the fan worked, more than the likely the thermoswitch is the culprit and the relay is fine. I had the same issue with mine, it became intermittent then just flat out quit. I have a 2016 btw, and it still went bad. The new one I got from my local dealer was a different brand and had some minor differences. Been in for about a month and no issues of far. Use the honda brand coolant that comes in the blue bottle. It's a different color but completely equivalent.

[Karmis]

So I did some testing today. Switched out relays, no fan. Jumped temp switch, fan. Easy fix.  Does anyone have the part number for the aftermarket direct replacement?
Oval plug.

[Karmis]

after doing a lot of research, I could not find an aftermarket thermoswitch.. I ended up buying 2 new ones from alpha motorsports. With shipping it was $50.00. Everything is working great now. I also wired in a bypass manual switch just in case. It goes directly from a hot source to the fan. 
hopefully I never need it.

[bwzforce800]

NMKawierider/Clark , the thermo switch has a rubber o ring on it , do you recommend I put some teflon tape on threads also or no ? My 2nd thermo switch went Saturday about 30 miles from cabin we were staying at..  I had a jumper wire with me so I was able get back. I want wire a bypass , I'll just need a basic 2 terminal ON/OFF toggle switch and 18 or 22 g wire correct ? Just quick connect to the 2 switch wires and run to the toggle switch?

[NMKawierider]

NMKawierider/Clark , the thermo switch has a rubber o ring on it , do you recommend I put some teflon tape on threads also or no ? My 2nd thermo switch went Saturday about 30 miles from cabin we were staying at..  I had a jumper wire with me so I was able get back. I want wire a bypass , I'll just need a basic 2 terminal ON/OFF toggle switch and 18 or 22 g wire correct ? Just quick connect to the 2 switch wires and run to the toggle switch?

Yep..all the thermoswitch does is jumper the two together so any switch that does that will do it. I have a write-up in the How To section on how I did mine. On the threads..no..I wouldn't. They aren't a tapered pipe-type thread so it won't really do anything.

So..that's two yours went through? If it does it again replace the fan relay. Some have found that the relay coil on some are pulling too many milliamps (ma) and that causes the thermoswitch to be over loaded and toast itself.