Reattaching thermostat wire - Snowmobile Forum: Your #1 Snowmobile Forum

i_play_bass · 01-20-2012, 12:04 PM

I noticed that the wire running from my thermostat to the indicator light was broken. I'd just re-solder it to the thermostat but it looks like epoxy was used to keep it attached in the first place and now that's stuck solid. Any recommendations on how to remove the epoxy (cutting, filing, heating?) so I can get in to solder it again?

The wire is broken just inside of the epoxy. Maybe my best bet is to just file down the epoxy until I can get at the wire left there, tie the wire together and solder it at that point, then electrical tape it... I know it's not ideal but might be easier than digging away all the epoxy.

'93 Indy Classic 500

bakon · 01-20-2012, 09:51 PM

I had a friend do a similar repair like this, it worked for a bit then the vibration caused it to break off. The wire needs some slack. You might have to dig deeper.

i_play_bass · 01-20-2012, 10:36 PM

Yeah, the epoxy is likely something like JB Weld, and it says that it can only be removed by filing or sanding... I've never done work on a thermostat. Does removing it allow coolant to come out? It would be a lot easier to work on/file off the epoxy if it wasn't attached to the engine. How fragile is the thermostat anyway? i don't want to be trying to file off epoxy and wreck the thing...

Edit - I guess the technical term for the thermostat is the thermal switch. I really just want to know the easiest way of making sure this thing is working right, without just replacing it. I will just buy one second hand on ebay if i have to though...

i_play_bass · 11-09-2012, 01:44 PM

This is still an unresolved issue on my sled, wondering if anyone has some insight on how to either remove the epoxy or to re-attach the wires? I don't know what the connection looks like underneath the epoxy... is it a rubber male/female connection, or are the wires actually supposed to be soldered to the thermal switch?

joshkidner · 11-10-2012, 04:21 PM

id file it down until you find bare metal and solder it. where is the thermostat located? mine needs same done lol (wire ran from thermostat to indicator light)

i_play_bass · 11-30-2012, 02:59 PM

I decided instead of dealing with filing down and everything I'm just buying a second hand temp. sensor with wire in tact for cheap from a guy with a junked sled. Is there anything I should expect when pulling that sensor off? I don't know if it runs directly into the cooling chambers inside the cylinders or what... I just don't want to make a mess of the whole thing.

Thanks!

steepndeep · 12-02-2012, 12:23 AM

The temperature sending unit should screw into the water jacket just below your radiator cap. A large deepwell socket should work fine. Use teflon tape on threads when you install it.

i_play_bass · 01-24-2013, 11:32 AM

Ok, so since a friend of mine had my carbs out to clean I replaced the thermal switch with a used one I picked up... The old one was shattered below the epoxy and fell apart while removing it, so obviously wasn't working... While I was putting the new one on the terminal that sticks out of the switch snapped off. It was barely even touched! I really don't want to spend $100 to get a new switch, but that's kind of an important indicator to have on the dash... The post is still attached to the wire. Would a simple soldering do the trick here to complete the circuit or is that just going to be useless?

**BC_Dan** · 01-24-2013, 12:10 PM

I doubt that any soldered joint will hold up to the vibration of the engine. You had the OEM one fail and the one you purchased had the same issues. It stinks, but I'm thinking that a new sensor is in your future. Babbitts has it for less than the 100 bucks. (about $70, which is still pretty spendy!)

1993 Polaris CLASSIC (0930864) Cylinder Assembly Classic / & Classic Touring / 0930865 | Babbitts Polaris Parts House

i_play_bass · 01-24-2013, 12:31 PM

Last winter I was going to order a couple of new exhaust and gas tank springs and the rubber exhaust pipe hat that sits in the belly pan from Babbitt's. Total cost was $16. When I put in my shipping information to PEI, Canada it came up to $106!! I emailed asking if this was accurate and they emailed back saying it costs $80 to $140 to ship anything internationally.

Let me tell you I would have had a few choice words for them, but decided not to reply...

It'll be a cold day in hell before I pay $100 to ship something that small! Canadians get a raw deal on buying anything across borders...

**BC_Dan** · 01-24-2013, 09:30 PM

$100! Yikes! That's insane. I keep forgetting about that pesky border between Canada and the US. Dang.

i_play_bass · 01-25-2013, 06:51 AM

Yep. That was my reaction too, but you left out a bunch of the four-letter words I used!
It's never usually that bad. Normally like $10-$20 to ship anything bought on ebay for example unless its heavy/big.

I'll figure something out though.

Side question - Is there any way to wire the accessory light to after market hand warmers? I had to ruin the stock one on the right side when I replaced the throttle block and I just bought Kimpex ones and wired them according to the instructions. They work fine but I never tried to see if I could get them connected to the dash light...