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Discussion Starter #1
Let me begin by saying hello. I have lurked for awhile and really enjoy the site. Lots of great info and conversation. I own a 2000 Polaris 500 magnum. It has very few hours and is in really good shape, the battery has been dead 4 several years, but I don't ride often and it usually starts on the second pull, so I took the lazy way out and just pull start it. That being said, about a week ago I tried to pull it and it just wouldn't start so I hooked it up to the battery charger and being in a hurry cranked it up to 50 to get the atv started. Once it starte running it ran great as usual while I rode it, but as I was putting it up It started boiling water out the side. I don't think that the fan ever kicked on. My question is whether you think the charger may have fried the fan or fan relay or whatever Polaris uses. I can't find any fuses. Sorry for the long post but I wanted to make sure all the info was here. Thanks!
 

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when you said "cranked it up to 50" what do you mean exactly. typically a battery charger has three charge setting. 6V 6AMP, 12V 6AMP, 12V 12AMP.

and where was it boiling water out of exactly. side of the motor, side of the radiator? if it was on the motor was it near the thermostat housing?

sorry for the quesitons, just trying to get a better idea
 

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And welcome to the board!
 

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Discussion Starter #4
My charger is a 12 volt with 2, 10, and 50 amp increments. I had it set at 50 amp or start. I also use this charger to charge trolling motor batteries set at marine deep cycle on 2. The water was coming from the left side near the plastic bottle that holds the coolant. I just removed the plastic panel and that bottle is almost empty. The radiator is still topped off. Hope this helps you help me! Also the fan did not come on for the whole 20 minutes I was riding, and it usually does. Thanks for the welcome!!!
 

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i have a feeling i know what is up.

below is a microfiche of your cooling system. part #42 is a 10 AMP circuit breaker for the fan. my guess is you popped it when you put the charger on it. doesnt really show where is is located, but your best bet would be start with the wires coming out of the fan and go on from there.



1 7080696 CLAMP,HOSE,1.25,WORM DRIVE 2 Usage
1 7080696 CLAMP,HOSE,1.25,WORM DRIVE 2 Usage
2 1240044 CAP-PRESSURE,13 PSI 1 Usage
3 5433364 FILLER-REMOTE COOLANT 1 Usage
4 5243505-067 BRKT,REMOTE COOLANT FILL 1 Usage
5 7661638 RIVET,INTERLOCK,B(50) 3 Usage
6 5433707 FLEXGUARD Substituted by 5433948 1 Usage
7 5411794 HOSE,UPPER ENGINE 1 Usage
8 7080827 CLAMP-ROTO SPRING 1" 2 Usage
8 7080827 CLAMP-ROTO SPRING 1" 2 Usage
9 7512024 SCREW,(10) 2 Usage
10 5411632 HOSE,FILLER NECK 1 Usage
11 7080826 CLAMP-ROTO CLIP 2 Usage
11 7080826 CLAMP-ROTO CLIP 2 Usage
12 7517659 SCREW 4 Usage
13 2410123 FAN&MOTOR,ASM,SPAL 1 Usage
14 7670111 CLIP,U,ZY 4 Usage
14 7670111 CLIP,U,ZY 4 Usage
15 7547069 NUTSERT,HEX(10) 2 Usage
16 7558301 WASHER(10) 2 Usage
17 3110032 MOUNT, RUBBER 2 Usage
18 5020572 SPACER, MOUNT 2 Usage
19 5433059 SHROUD-FAN,ATV 1 Usage
20 4010161 SENSOR-THERMAL/HARNESS 1 Usage
21 1240045 RADIATOR 1 Usage
22 7552605 WASHER(10) 2 Usage
23 7512113 SCREW(10) 2 Usage
24 5433317 COVER-RADIATOR,W/MESH 1 Usage
25 5410607 O RING 4 Usage
26 7052244 VALVE-PLASTIC DRAIN 1 Usage
26 7052244 VALVE-PLASTIC DRAIN 1 Usage
26 5411633 O-RING,BUNA [No Longer Available] 1 Usage
26 5411633 O-RING,BUNA [No Longer Available] 1 Usage
27 5410584 BUSHING,MT,LOW RED 2 Usage
28 5243503-067 BRKT,RADIATOR,LOWER,BLK 1 Usage
29 7517386 SCREW,(10) 3 Usage
29 7517386 SCREW,(10) 3 Usage
30 5411694 HOSE,LOWER ENGINE 1 Usage
31 5521511 GUARD-HOSE,12" 1 Usage
32 5244064-067 BRACKET-COOLANT HOSE MOUNT,BLK 1 Usage
33 7080807 CLAMP-HOSE 1 Usage
34 ------- Screw (See Front Housing Pg C11, Ref. 2) 1 Usage
35 8450003-1525 FUEL LINE,1/4 ID(1525 CM.) 1 Usage
36 7052065 FITTING,90 DEGREE 1 Usage
37 7512084 SCREW(10) 2 Usage
38 5433410 TANK,SURGE 1 Usage
39 5433774 CAP,PLUG9X(GRN),FLEX TEMP(10) 1 Usage
40 5810279 GASKET 1 Usage
41 5430743 CAP, OVERFLOW 1 Usage
42 4010369 BREAKER,CIRCUT,10A,FAN [No Longer Available]
 

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Discussion Starter #8
Well, I found the connection where I think it may be, but I can't figure out how to get it apart. There is no latch like you find on cars sensors. I am afraid to put too much muscle into it for fear of breaking it. I have tried putting a small screwdriver in and prying gently but it won't budge.
 

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hhmmm, i am not to sure, i havent personally had experince with this. maybe someone on this board has done this or a quick google search might net you some info
 

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the circuit breaker should be sealed in some sort of rubber, like a bike tube. it's a small rectangle halk the size of a 9 volt battery and will have one wire going to it and one leaving. The circuit breaker will have what looks like 2 bolt ends on it. Good luck finding one of the same circuit breakers, all I did was rewire it to use a fuse and everyonce in a while the fuse will pop so just carry a couple extra ones
 

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Can anybody tell me where to find that breaker......my fan is not turning ON (2010 Sportsman 500 HO)

thanks
Eric
the circuit breaker should be sealed in some sort of rubber, like a bike tube. it's a small rectangle halk the size of a 9 volt battery and will have one wire going to it and one leaving. The circuit breaker will have what looks like 2 bolt ends on it. Good luck finding one of the same circuit breakers, all I did was rewire it to use a fuse and everyonce in a while the fuse will pop so just carry a couple extra ones
 

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locationg of fuse

when you look at the headlight theres a piece of plastic just under it the colour of your bike, lift that piece off and its in there. I was able to find a circuit breaker at canadian tire after searching a few because the fuses kept triping. i'm actually not sure if your bike even has one though i think there only on the EFIs but i could be wrong
 

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gotta a 2011 razor s 800 fan quit working...i hear ther is a relay that could b the problem but dont know wher it is exactly...under the drivers seat im told..and wut does it look like..going to test fan to c if it is the problem but would like to know bout this relay
 
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