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I have a 96 sportsman that i just replaced the radiator with one from amazon, and i have the fan sensor tightened all the way in and it still has a small leak. Do i need to apply more teflon tape to it or is the fitting messed up?
 

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I believe the tank is plastic - inspect it closely for a crack which happens easily if the sensor is over tightened - if there is no crack, remove the sensor and ditch the tape - get some Locktite Pipe Thread Sealant, clean and dry the threads on the tank and sensor, apply the sealant to the first two threads of the sensor, screw it into the tank and tighten it with pliers (not a wrench), it only needs to be snug (tight enough that it cannot be turned by hand but not "torqued") - as insurance you might fashion a large flat washer from 24 gauge sheet metal and put an o-ring between the washer and the tank - if there is a crack in the tank, you can try any number of sealants and methods of repair, but it will be best to get a different radiator.
 
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