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Then it's either an intermittent wiring issue, a glitch in the ECU, or possibly a bad "new" sensor.

Oh and possibly bad contacts where the relay plugs in.
 

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I put a toggle switch on my 2003 R1 because the fan didnt come on until it was 212° by that time I was roasting chest nuts. Never had any issues with it. Just an idea..
 

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not my MO but a ive heard of guys doing it and its effective.
 

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I just bought a 07 sportsman 800 x2 and it over heats when I go slow I noticed the fan dont always come on especially when I have the key on the on position I got to turn it back like 4x to get it to come on and when the hot light is on it runs sometimes when it wants to ..I got a new thermister on it any Idea what it is
Please help..

And also sometimes it drops to 300 rpm and does at idle
I have experienced a problem with a air pocket getting trapped and the temp sensor not turning the fan on. This is especially true if it has overheated and blew water out. Sounds like you may have some sort of wiring issue
 
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