I have tried jumping the fan at the relay terminals and it for sure turns on, i do have new thermal switches in but they sent me 2 for my 800 when i was suppose to get 1 for each bike, anyone know if the 800 thermal switch will fit in the 500 trail tracker if i change the connector?

ive been researching the temperature sensor more and in the terralander manual one of the steps it says when diagnosing the fan not coming on is check the CTS and replace if not working. now ive been told the fan switch and the cts are not connected at all, i cant even see on the wire diagram how they would be connected. does anyone know why the manual would recommend this step?

[2015 Z Force 800 53/Trail EPS]

I have tried jumping the fan at the relay terminals and it for sure turns on, i do have new thermal switches in but they sent me 2 for my 800 when i was suppose to get 1 for each bike, anyone know if the 800 thermal switch will fit in the 500 trail tracker if i change the connector?

ive been researching the temperature sensor more and in the terralander manual one of the steps it says when diagnosing the fan not coming on is check the CTS and replace if not working. now ive been told the fan switch and the cts are not connected at all, i cant even see on the wire diagram how they would be connected. does anyone know why the manual would recommend this step?

The Chinese are not that good at translating their manuals to English and you will fins lots of errors. What exactly is a CTS?

Cooling temperature sensor

[2015 Z Force 800 53/Trail EPS]

Cooling temperature sensor

Ahh..and on the newer..2018+ I believe, they deleted the POS thermoswitch and are now using the ECU to control the fan relay and it...gets its data from the "CTS" as in this diagram.

if you haven't replaced the thermoswitch do it because the can go bad and stop working. the fan will fork if you take the conector out of the thermo switch and put something that leads the electricity to both pins in the conector on the cable and the fan will start even with the termoswitch does not work.   You maybe need to clean the temp sensor conector with some electrical spray if it somehow have com in som water or moister in the temperature gauge.

I second cleaning the temperature gauge sensor connector, its on top of the engine at the thermostat housing. remove your intake cover between the seat to access the connector. My temperature gauge malfunctioned a few rides ago, it was reading one bar most of the day, the engine fan was kicking in out as normal. I cleaned the terminals with CRC 05103 QD cleaner, coated everything with Permatex Dielectric grease, reconnected and all was working as normal, three to four bars and fan kicks in.

As far as the EPS light flashing, I had that issue the first week i had it. After looking around in the dash there is a red wire from the ECU that has a butt connector in it which came unplugged. I plugged it back in and crimped it slightly and wrapped it in electrical tape to keep it together. The light went out and no issue since.

[2015 Z Force 800 53/Trail EPS]

sorry haven't updated seems like my water pump was leaking again looks like the water pump seal I was sent wasn't the proper one so my new seal and gasket should be in any day fingers crossed. hoping once I have the proper seal and gasket i can finally get this issue under control. While I was running the atv with a leaking water pump and a new rad switch the rad fan still wasn't coming on, coolant was circulating and heating up. I'm fairly certain the coolant was hot enough but next time I am going to use a thermometer to see how hot its getting, I am paranoid of doing damage by letting it run too long without the fan.

Remember to have NO air gap between the fluid and cap and most of them won't come on until the high-end of the third bar.

[2015 Z Force 800 53/Trail EPS]

ah ok feel kind of stupid now ive had the rad cap off so I could watch to see if any air bubbles were rising. I guess me having the cap off is preventing the temperature from rising high enough? heading out after work today to work on it more.

No..it will still get hot enough without the cap on.

I've had the same weep of antifreeze since new in 2017 and it hasn't added up to more than a pint in all that time (1300 miles).

I just ignore it for the most part.

[2015 Z Force 800 53/Trail EPS]

Bad ground probably.