Recently I had an overheating issue with our 2007 Polaris Sportsman 800.
After riding about 3-4 miles at a slow pace the digital display would read HOT, the fan would kick on and off but it was definitely overheating.
I could remove the plastic front radiator shoud and ride fast and it would take a lot longer to overheat.
As I was sitting there the fan would sound like it was trying to come on and sometimes would ,sometimes it wouldnt.
I noticed some corrosion forming on the fuses and the 2 releays even though they had dielectric grease from the factory. I cleaned them and re-greased them but the overheat problem was still there.
I tried another releay out of my ford truck, fans worked but still overheating.
It was acting like a bad cooling fan motor but...
Come to find out, after tracing the cooling fan circuit back...
under the headlight pod, behind the fuse box there is a thick black sealed plastic bag with a red wire going in and out of it.
I cut open the bag and found a badly rusted 12 volt 20 amp circuit breaker.
I cut it out, installed a 12 volt inline fuse holder, put a 12 volt 30 amp circuit breaker out of a 1995 grand am in the fuse holder, taped the thing up and zip tied it to the harness in the headlight pod to keep it away from the mud and moisture.
The breaker I used is a common breaker used in GM cars, it had terminals that lined up with the inline fuse holder, I had to trim the rubber away a bit.
Rode over 210 miles since then with no problems.
Here are some pics, Supposedly sealed in a weatherproof pouch
