polaris rzr fan circuit breaker

No_Substitue_For_A_Brute · 03-22-2012, 11:24 AM

In an attempt to get my fan back working I realized we did not have any how to's on this topic so here goes my attempt to maybe help someone with this issue in the future. Sorry the pictures were taken as an afterthought but should be pretty clear.

All current brutes 05-12 Carb and EFI have a small breaker in the fan circuit. These breakers tend to corrode, stop working, or have the prongs break off. You can eliminate this issue by replacing it with an in line fuse.

The breaker can be found just behind the solenoid switch. There should be a white wire and a blue wire with white stripe going to it. As you can see my white wire broke off.
IMAG0268.jpg IMAG0269.jpg

Given the harsh electrical conditions most of us put our bikes through with all the mud and water I decided to replace mine with a weather resistant fuse holder I could seal up and had a light if it blows. EasyID by Bussman part# BP/ATM-FHID.
IMAG0265.jpg

Disconnect your positive battery cable before working on the breaker as it has power even with the key off. Simply cut the two wires that went to the breaker and connect them to your fuse holder. I chose to use butt connectors with heat shrink ends built in but they can be done however you want as long as it has a solid connection.
IMAG0263.jpg

The original breaker is a 10 amp breaker so put a 10 amp fuse back in the holder. You can now test it and see if it works. If you already have a manual fan switch it will be much easier to test. Here is a link for the different setups:
MudInMyBlood Forums - View Single Post - Radiator Fan Switch (Just one more version)

Once you know everything works I recommend sealing the holder to prevent and future corrosion issues with the fuse. I opened the holder and put silicone around it then closed the top and smeared it around the edges.
IMAG0267.jpg

Note: The fuse holder I chose uses ATM type fuses not the ATC type that are in the fuse block already. I couldn't find one that carried ATC fuses that was weather resistant when I went to buy mine. Using an ATC one would be better since that would keep all your fuses the same type for easy sparing and field fixes.

Polaris425 · 03-22-2012, 11:28 AM

Thanks!

filthyredneck · 03-22-2012, 11:34 AM

Nice write-up....as many times as we've covered this I can't believe we just now have an actual How-To for it lol.

brutemike · 03-22-2012, 08:45 PM

Good write like filthy said surprised we didn't have it already.

commando tapatalk

No_Substitue_For_A_Brute · 03-22-2012, 09:05 PM

Thanks guys. Hopefully someone gets some use out of it.

Sent from my ADR6400L using Tapatalk

BrutemanAl · 03-23-2012, 03:49 AM

I'll get use out of it for sure , been wanting to do this for a while , just never really got around to it .

Awesome job on the "how to" by the way

I love this site !!!

NYBrute · 03-26-2012, 05:19 AM

Great write up! This is the most informative site I've ever been on. And nobody bashes anybodies ideas or trys to one up them. I actually know that I can do some of these jobs on my Brute now that would normally have sent it back to the dealer for repair. Thanks for the great forum. I tip my muddy hat to you fellas.

MakingSumXs · 04-02-2012, 07:55 AM

I will use this this week for sure. The inline switch and fuse, along with a rad relocation and I'll be ready to go!

lilbigtonka · 04-03-2012, 06:41 PM

just had to do this to my buddies bike as his white wire broke/corroded right off now works like a charm......this is def a good writeup and simple mod

lukan12 · 04-16-2012, 12:09 AM

my breaker broke today and i just found this and this is so easy don't know why i never thought of this!!

Mr.Scruffy · 07-03-2012, 06:48 AM

Found this and fixed mine last night. Now for the other 99 electrical prob's.

MY07BRUTE · 07-11-2012, 11:33 AM

ATC waterproof fuse holder

Littlefuse Phac0001zxj Inline Fuse Holder ATC Motorcycle Waterpoof 16 GA, #fsb15

or

Waterproof fuse holder for ATO/ATC fuses up to 30 Amps

No_Substitue_For_A_Brute · 08-08-2012, 04:14 PM

Quote:

Originally Posted by No_Substitue_For_A_Brute

Note: The fuse holder I chose uses ATM type fuses not the ATC type that are in the fuse block already. I couldn't find one that carried ATC fuses that was weather resistant when I went to buy mine. Using an ATC one would be better since that would keep all your fuses the same type for easy sparing and field fixes.

FYI I learned a couple weeks ago that the new 2012 Brutes use the small ATM fuses for it's new fuse block. So for 2012s the fuse holder I used above would be the perfect match so all the fuses are the same for ease of sparring.

03-22-2012, 11:24 AM	#1
No_Substitue_For_A_Brute Experienced Mudder Join Date: May 2011 Location: South Georgia	How to: Replace fan breaker with fuse In an attempt to get my fan back working I realized we did not have any how to's on this topic so here goes my attempt to maybe help someone with this issue in the future. Sorry the pictures were taken as an afterthought but should be pretty clear. All current brutes 05-12 Carb and EFI have a small breaker in the fan circuit. These breakers tend to corrode, stop working, or have the prongs break off. You can eliminate this issue by replacing it with an in line fuse. The breaker can be found just behind the solenoid switch. There should be a white wire and a blue wire with white stripe going to it. As you can see my white wire broke off. IMAG0268.jpg IMAG0269.jpg Given the harsh electrical conditions most of us put our bikes through with all the mud and water I decided to replace mine with a weather resistant fuse holder I could seal up and had a light if it blows. EasyID by Bussman part# BP/ATM-FHID. IMAG0265.jpg Disconnect your positive battery cable before working on the breaker as it has power even with the key off. Simply cut the two wires that went to the breaker and connect them to your fuse holder. I chose to use butt connectors with heat shrink ends built in but they can be done however you want as long as it has a solid connection. IMAG0263.jpg The original breaker is a 10 amp breaker so put a 10 amp fuse back in the holder. You can now test it and see if it works. If you already have a manual fan switch it will be much easier to test. Here is a link for the different setups: MudInMyBlood Forums - View Single Post - Radiator Fan Switch (Just one more version) Once you know everything works I recommend sealing the holder to prevent and future corrosion issues with the fuse. I opened the holder and put silicone around it then closed the top and smeared it around the edges. IMAG0267.jpg Note: The fuse holder I chose uses ATM type fuses not the ATC type that are in the fuse block already. I couldn't find one that carried ATC fuses that was weather resistant when I went to buy mine. Using an ATC one would be better since that would keep all your fuses the same type for easy sparing and field fixes.
	__________________________ 2005 Kawasaki Brute Force 750i 29.5" outlaws all wide on ITP wheels HMF Swamp Series with custom full exhaust front pipe RDC 2" lift & moose power module custom 2" snorkels Buss connector Mod VFJ Stage 3 clutch, VFJ #1/#2 springs ASR tie rods, Rhino axles in the rear
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03-22-2012, 11:28 AM	#2
Polaris425 Forum Admin. Join Date: Dec 2004 Location: Tuscaloosa, Al Images: 77	Thanks!
	__________________________ MIMB - The REAL "Brute Central" Sold: '00 Polaris Xpedition 425 Sold: '86 Honda 350X Trike Sold: '00 Polaris Scrambler 500 4x4 Sold: '07 Brute 750 Now: 2011 Camo LE TeRyx - MIMB Snorks, MIMB Foot Pedal Mod, 4000# Viper Max www.MudInMyBlood.com We Have a Thread for That...
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03-22-2012, 11:34 AM	#3
filthyredneck GET FILTHY OR GO HOME! Join Date: Feb 2010 Location: Dayton, Tx Images: 31	Nice write-up....as many times as we've covered this I can't believe we just now have an actual How-To for it lol.
	__________________________ 11' Renegade 800 XC P-ATV snorks, PC-5, /// CV Tech Primary + 650 helix, Viper Max 4K, 31 LAWS/Beadlocks & 1.5" spacers 09' RZR-S 800 DragonFire Dual Exhaust, DragonFire Programmer, Snork'd Carbon Fiber Hood w/dual scoops, Kicker 6.5s, FRN's Chopped Cage FOX Shocks/SuperATV HD Springs, QSC clutch kit, 31 LAWS/Beadlocks TEAM SCREW IT UP
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03-22-2012, 08:45 PM	#4
brutemike Professional Mudder Join Date: Mar 2010 Location: southwestern PA	Good write like filthy said surprised we didn't have it already. commando tapatalk
	__________________________ 2011 750 brute custom racked rad 3" mimb center snorkels maroon primary & red secondary 2" RDC lift, oil cooler 29.5" outlaw2's on ss212's 1.5 wheel spacers back only split audio tubes penloc,grease zerks viper max 4500
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03-22-2012, 09:05 PM	#5
No_Substitue_For_A_Brute Experienced Mudder Join Date: May 2011 Location: South Georgia	Thanks guys. Hopefully someone gets some use out of it. Sent from my ADR6400L using Tapatalk
	__________________________ 2005 Kawasaki Brute Force 750i 29.5" outlaws all wide on ITP wheels HMF Swamp Series with custom full exhaust front pipe RDC 2" lift & moose power module custom 2" snorkels Buss connector Mod VFJ Stage 3 clutch, VFJ #1/#2 springs ASR tie rods, Rhino axles in the rear
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03-23-2012, 03:49 AM	#6
BrutemanAl Rollin' Deep Join Date: Jul 2009 Location: Codrington,Ontario Images: 5	I'll get use out of it for sure , been wanting to do this for a while , just never really got around to it . Awesome job on the "how to" by the way I love this site !!!
	__________________________ 2008 Brute Force 650 I Super Black , 27" MudZilla's on SS 212 chrome rim's , Floor board protector's , CDI Dyna Tech , HDPE full Skid Plate (custom made) and custom made A-arm guards , Diamond G tie rods , 2 inch lift kit , 2500lb warn winch , , front storage box mod , grease fitting mod on all a-arms ,Temp Gauge Mod and fan Toggle switch , Wild Boar Rad Relocate , MIMB 2" Snorkels, eTrex legend gps , 5 ' Easy Mount Plow
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03-26-2012, 05:19 AM	#7
NYBrute Newbie Join Date: Oct 2011 Location: Upstate NY, in the foothills to the Adirondacks	Great write up! This is the most informative site I've ever been on. And nobody bashes anybodies ideas or trys to one up them. I actually know that I can do some of these jobs on my Brute now that would normally have sent it back to the dealer for repair. Thanks for the great forum. I tip my muddy hat to you fellas.

Feedback: (0)

04-02-2012, 07:55 AM	#8
MakingSumXs Newbie Join Date: Mar 2012	I will use this this week for sure. The inline switch and fuse, along with a rad relocation and I'll be ready to go!
MakingSumXs Newbie Join Date: Mar 2012
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04-03-2012, 06:41 PM	#9
lilbigtonka Honored Member Join Date: Dec 2008 Location: Arcadia, FL	just had to do this to my buddies bike as his white wire broke/corroded right off now works like a charm......this is def a good writeup and simple mod
	__________________________ 08 Brute Force 750i Black Octanes wrapped in Monsters \| RDC 2in lift \| ASR Tie Rods \| Decals Gone \| MIMB Snork's \| 8in Split Tubes \| Blue leds in headlights \| Relocated Radiator \| Powdercoated racks to match \| VFJ stage 3 \| Skid Plates powdercoated \| Custom Bash Plate Powdercoated \| Ram Mount for Otterbox \| Mudslinger exhaust \| MSD \| Custom Shift Knob \| Manual fan switch \| inline temp gauge \| ODI grips \| Backrest \| 07 springs and shocks, its complete til the next mod 2000 Honda 300FW The Submarine nuff said
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04-16-2012, 12:09 AM	#10
lukan12 Newbie Join Date: Apr 2012 Location: slave ,lake AB,canada	my breaker broke today and i just found this and this is so easy don't know why i never thought of this!!

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07-03-2012, 06:48 AM	#11
Mr.Scruffy Trail Rider Join Date: Jun 2012 Location: Orange, Texas	Found this and fixed mine last night. Now for the other 99 electrical prob's.
	__________________________ 2007 Brute Force VF650H - Inherited from oldest son. It is beat up, wore out, well seasoned, wired and spliced together front to rear, duct taped and still runs like a scalded dog.
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07-11-2012, 11:33 AM	#12
MY07BRUTE Trail Rider Join Date: May 2011 Location: NY	ATC waterproof fuse holder Littlefuse Phac0001zxj Inline Fuse Holder ATC Motorcycle Waterpoof 16 GA, #fsb15 or Waterproof fuse holder for ATO/ATC fuses up to 30 Amps
MY07BRUTE Trail Rider Join Date: May 2011 Location: NY	__________________________ 07' Brute 750i (Black): Power: Dynatec CDI, UNI air filter, Dynojet kit, Full Big Gun. Traction: 26" Bighorns/black ITP type 7 beadlocks, Poly swaybar mod, ASR tie rods. Other: ODI Rouge grips, Amber LED "Parking lights" and 5K D.I.Y. HID's, 08'+ Storage box, deflectashield Rear Black alum. Box, Viper MAX 3000 Syn', American Eagle 60" Std. plow 08' Dodge RAM PowerWagon (Laramie, 6 Speed) intake, exhaust, chip, etc...
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