Need Advice for those more in the mechanical know

Incoming wall of text

I had my topend redone after the April ride -took 2 months but that is another story.

Also have had issues where I wiggle the wire bundle where all the fuses are to make the fan kick on.

First Ride out (10 miles into the trail)- Vapor lock so bad the top small clear hose that that comes back from the radiator cap burst -then it reported being hot. So hot the coolant was boiling.

As soon as I get the RZR out of the woods went to Autozone and replaced hose with new black coolant hose, flush entire cooling system and replace with Prestone 50/50 -bled all air out.

Works beautiful on flat ground or just sitting there - coolant circulates etc..
Fan kicks on /off as it is supposed to.

Goto Brimstone a few weeks ago
On the first day out everything is fine until I co up a steep incline - Hot light flashing, fan is not running. Stop at top of hill undo radiator cap - no air in system, coolant is circulating but the fan is not running even though the HOT light is flashing.
This continued to happen the rest of the day, but only when going up big inclines or sitting idle. Fan relay is extremely hot and makes an audible click when fan turns on /off -never heard this before i don't think.

Go back to hotel - cutoff fan plug and rig two wires (fused) to manual run the fan while driving - no flashing lights the rest of the trip.

Buddy who rebuilds engines etc.. thinks it's a bad fan relay or thermister.
Took it to the dealer who can't find anything wrong because it is on level ground not under load ie. fan clicks on/off as supposed and coolant circulates. Can't find anything wrong with electrical. The dealer has had it for 3 weeks and I am picking up tomorrow.

What would you do? I want to have fun on the upcoming trip and not hold everyone back?. I could wire a fan switch, but I shouldn't have to.
Dealer does not have a relay or thermistor in stock.

thoughts?

http://www.utvcrap.com/product_info.php?products_id=3427

Kinda new here but you can check the thermostat by putting it into a pot of water with a thermometer and putting it on the stove. You can tell when the thermostat opens and check the thermometer, I am not so sure what temp it should be but most gasoline cars are set around 180.

I think I would wire it to a switch so you could run it when needed to be safe but I don't know much on the subject

i would wire it on a switch for now and order the relay. it wont hurt to run the fan all day.

Ordered this: http://www.quadovator.com/1618702.html

Trying to fins some place that has a relay in stock to overnight.

Thanks for the input, was already leaning on the switch / relay.

That should help

Got it yesterday and installed. Kinda cool actually.