01 Sportsman 400 Overheating - Polaris ATV Forum
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post #1 of 11 (permalink) Old 07-14-2019, 12:29 PM Thread Starter
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01 Sportsman 400 Overheating

I am looking for some help as my sportsman 400 has recently started overheating. I installed a toggle switch and direct wired the fan as I had thought that may help fix the issue and I thought it was working but then started overheating again. I am looking for suggestions on what to try next? Should I test the thermostat or with the fan being direct wired will that make no difference? Thanks for any help.
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post #2 of 11 (permalink) Old 07-14-2019, 01:41 PM
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Hey brother I'm in the same boat, i have a 2018 polaris 450 sportsman H.O and it just started over heating yesterday while setting up some new deer stands.......only have 112 miles on it......first thing they told me was to clean the radiator i did that and now i don't think the fan works.......im trying to figure it out to if i get mine going or come across some helpful info ill let you know.
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post #3 of 11 (permalink) Old 07-14-2019, 01:43 PM
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check your thermostat

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post #4 of 11 (permalink) Old 07-14-2019, 03:20 PM Thread Starter
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So even with the fan on a toggle so I can run it all the time, if the thermo is bad will it still cause overheating?
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post #5 of 11 (permalink) Old 07-14-2019, 03:45 PM
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Quote:
Originally Posted by jbronson1 View Post
So even with the fan on a toggle so I can run it all the time, if the thermo is bad will it still cause overheating?
If the thermostat doesn't open no coolant ever flows through the radiator to be cooled. It wouldn't matter if you had two or three fans blowing all the time.
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post #6 of 11 (permalink) Old 07-14-2019, 05:13 PM Thread Starter
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I just want to make sure I'm clear. You're talking about the thermostat in the bottom right corner of the radiator, correct? I removed it today but was not sure how to test it as it does not have a valve or anything on it but is almost like a solid plug. I have attached a picture to show what it looks like.
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post #7 of 11 (permalink) Old 07-14-2019, 05:18 PM Thread Starter
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Or should I be looking at the thermostat on the engine itself?
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post #8 of 11 (permalink) Old 07-14-2019, 07:36 PM
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What you have pictured is a thermal fan switch. Its a simple switch that turns the fan on at around 197 degrees and off at around 180. The thermostat is located on the left side of the engine cylinder inside a fitting for the coolant line that goes to the radiator. It opens at a around 180 degrees to allow coolant to flow to the radiator. Its number 3 in the diagram below part number 3084940.
Here's a link to a thermostat for your machine on ebay and a picture of its location.
https://www.ebay.com/itm/Thermostat-...95dc10e5de362f
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post #9 of 11 (permalink) Old 07-14-2019, 07:39 PM
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The thermo switch number 4 in the diagram and location picture just below the thermostat turns the hot light on when the machine overheats.
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post #10 of 11 (permalink) Old 07-15-2019, 04:18 AM Thread Starter
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Thanks Polman500. I am going to pull the thermo today and test it. Does the thermo switch (#4) play any part in activating the thermostat or does it only relay to turn the light on? This light does not come on right now when the engine overheats and if I dont need it I would rather not buy it but if it plays another part then I will order one.
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