Cooling Fan Override


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This or any modification to your ATV, should be performed ONLY at your own risk.  DISCLAIMER

Before attempting any work, read the entire article first, to reduce surprizes.

Purpose of this modification:
To bypass the operation of the fan for on-command control. This can significantly reduce engine heat when vehicle movement is too slow for effective normal cooling.

Results to expect after successful competion of this modification:
Switchable functionality of the cooling fan.

Negative side effects of this modification:
None reported

Skill level:
Basic electrical

Tools required:
Basic hand tools

Parts or materials required:
SPST toggle switch (must be rated for 30 amp service), solderless wire taps, 14 or 12 guage automotive style wire, etc...

Approximate or estimated cost of mod:
$5


ThermoSwitch1
Locate the wiring and connector at "Thermoswitch 2" in the left rear side of the radiator.
(See photo at right)

It may be easier to use something to temporarily prop the body plastic out of the way. The left front tire could also be temporarily removed for more room to work.














ThermoSwitch 2
Unplug the connector to gain easier access to the 2 wires, Blue and Red / Black stripe. Be careful with the latch in the plug, they can be broken easily.




Fan Override diagram



Remove a few inches of black tape from the wire bundle. Apply "wire taps" (shown lower right) about 3 inches up the wires from the Thermoswitch-2 end connector.

Choose a suitable mounting place for your SPST toggle switch ((( 30 amp rated ))) and attach and route two wires from its terminals to the wire taps just installed above, (near the thermoswitch-2 connector).

(see wiring diagram at right).

Crimp on the connector counterparts of the wire taps to the ends of the new mod wires from the new switch. The type of connectors that are supplied with the part # shown in the photo (bottom right) are male spade terminals (pale blue part). The female (socket) part of the spade is intigrated into the (darker blue) "tap" part.

Be careful in choosing a route for the new wires to the new switch. Do not route in the vacinity of sharp edges or near the exhaust where the insulation could be compromised. Use Nylon Zip Ties to bundle the wires away from anything that could damage them.



I will try to remember to upload a couple of better photos the next time I am in that area and have a few minutes.





Wire Tap

Wire taps used to connect the SPST switch to the OEM wires. After your mod is wired and completed, don't forget to re-connect the connection to Thermoswitch -2  on the back of the radiator. Generous application of dielectric grease is advised on ALL parts and connections involved with this mod. Switch terminals, wire taps, Thermoswitch-2, etc...

After completing the mod, apply dielectric grease to any / all other connectors you can reach while your at it. It may well save you some electrical trouble later. Especially the 3 front diff electrical connectors.




The OEM fan control should still function normally whether you have the Mod switch on or off, if you have done everything correctly and reconnected OEM Thermoswitch-2.


This mod should not be used for continous operation of the fan. Extended periods of fan operation may cause premature wear/failure of the fan motor.
Use it when it is needed, then turn it off when it is no longer needed.