KymcoForum.com
Offroad => Side By Side => Topic started by: airshot on September 21, 2019, 02:50:25 PM
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I know this has been an issue with many other brands, but from my reading I havent heard much about Kymco having this issue. This past ride I had a boiling overheat issue after some long steep hill climbs and the fan not turning on. Normall I can hear my fan kick on but not now. I will be checking the fan and try ro find and check the thermal switch. If anyone has had this issue that could point me in the right direction that would help. Otherwise I will report back my findings when I get it figured out.
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EMI filter. I’ve had the same exact frustrating problem. Checked the thermal, bypassed the thermal, cleaned all connections, tested fan and it turned out to be the EMI filter which I thought was the relay.
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Thanks for the reply...however you need to educate me...what is an emi filter? Not familiar with that term..
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(https://uploads.tapatalk-cdn.com/20190921/3363d02f7d32d7cd29dde1a3c5214b2c.jpg)
Attaches to your fan located in front of your battery box and looks like a relay. Has two wires leads, male and feemale.
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It’s a electronic noise filter. Why they put those on there I have no clue. If you ask anyone about it they look at you like your crazy. Lol.
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My EMI filter was HUGE compared to that tiny relay-lookin' box! I guess the fan motor produces some offensive RFI so they put that filter on. Mine works great without it!
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I couldn’t tell a difference unless I had the speakers playing. Even then you had to me in between songs and really listening for it.
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Thanks for that info....now..I am not an electrician so..can this be removed or bypassed or does it need replaced? Is there a way to test it? If you can, how do you bypass it? Really appreciate any help you can give. Been a toolmaker for 50 yrs and can make anything but electronics is where I get lost.
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Yea you can just bypass it by connecting the two leads from the fan together. Run it and if don’t act up, there’s your problem. You can bypass the thermal sensor with a pice of wire. Your fan should run all the time then.
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Many thanks for that!!! Next question is..if you bypass the thermal sensor, are you connecting the wires that are in the sensor plug? Thinking of adding a switch to be able to activate the fan manually if the thermal switch evers fails. Looked in service manual and found everythings location but there is no mention of that filter that I can find.
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Yes the wires that run into the sensor that screws into the radiator. We have an old mule that we put a switch on. Works like a charm as long as I remember to flip the switch. Lol
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Sensor is not shown in the radiator, but shown near the head ...I am guessing that you jumper wire across the 2 wires in that plug....?
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Which model do you have?
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2015 450i UXV.
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In that pic I sent you can see it in the top right, has two wires connected to it. Your model could be on the motor I haven’t found a diagram yet. When I get to the office Monday I’ll check a web site I have saved. It’s got real detailed parts diagrams.
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In that pic I sent you can see it in the top right, has two wires connected to it. Your model could be on the motor I haven’t found a diagram yet. When I get to the office Monday I’ll check a web site I have saved. It’s got real detailed parts diagrams.
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I see four wires, two blue, two black.
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Your pic is different from my machine. My coolant bottle is in front of the radiator and the battery box is under drivers seat. There is a fan plug at bottom of rad but that wire then follows the frame back into the cab. If there is a filter it has to be under dash or under seat. I will keep looking...thanks for any info you can pass along!!
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Yea I was looking at that. I have a 2010 500 UXV LE so it’s an oldie but goodie. Heck yours may not have one, they may have figured out it was a joke. Lol! I do know that when and if your fuel pump goes out, most UTV fuel pumps are the same. The “KYMCO†was $125.00 and a 2 week shipping delay. I took mine old fuel pump to a ATV dealer and said I need one if these. $34.00 Out the door just had to splice the plug in. Also I found lift kits for them that are good quality, had to search to the end of the internet and back but found them.
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I think I may have found my fan problem, the fuse holder came off the clip beside the battery compartment and fell down in the engine compartment, for how long I have no idea but it was packed with mud and water. I could not get the top off without tapping out some of the crud. Backside where wires go in was also packed with crud. Fuses were difficult to remove and the contacts were corroded on all of them. Bought all new fuses and a nail file to get in there and clean the female contacts in the fuse holder. Put all new fuses in and everything seems to work. Will know more when I can get the buggy heated up for the fan to come on, but I had terrible contact with all the fuses. Factory fuses cant see whether blown or not but I am getting funky readings with the ohm meter. With all new tested fuses I am fairly confident I am good to go. Look carefully at your fuse holder on the back side of the battery compartment and make sure the fuse holder stays up there and out of the mud and crap. Many thanks to all that responded, hope this will be of help to others.
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May want to squeeze some Dielectric grease to both sides of your fuse box. I had that issue once and that helped a lot.
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Just an update, took our dog for a long slow ride on the 450i to get it hot and check to see if the fan would come on. It did...the mud packed fuse holder caused poor connections with corrosion. After a thorough cleaning and all new fuses we are good once again. I had some minor stalling issues when cold but even that has cleared up. Moral of this story....keep those electrical connections clean !!!