Fortunately the problem turned out to be a blown fan fuse. So now I am wondering what would cause the fan fuse to blow. I checked both fan blades and they spin freely.
Thanks for the comments. There has been a lot of tree debris on the country roads I travel. And the fuse was different from most blown fuses I have seen, usually just a clean gap. This one has a black burn mark and no gap that I can see with the naked eye. I had to test it with my multimeter to know it was blown.If the burn mark is off-center then it's almost certainly a vibration failure.
Swapping relay boxes didn't help. I'm going to pull the plastic and test the fans, I assume one of them must be bad. Waiting on an air filter since I might as well change it while the plastic is off.
Let them run 5 to 10 minutes and then feel if they get warm or not. If there are bad bushings or bearings they probably won’t show up immediately.Thanks for the suggestions. I only ran them for about 2 minutes each. I will run them longer. But I think this type of testing will not be very valid due to the large temperature difference testing off the bike. I think I recall from high school science that resistance goes up with the temperature. Also I probably have to rig a connection to run both fans at once.
Also, were you able to check the amperage draw on each one and then recheck them after they have run for that 5 to 10 minute period of time.
My $.02 worth.
At this point, I would inspect the wire harness for a possible grounding issue. Something has to be causing that fuse to pop. I know this could be a pita, but you could try rewiring (even if temporarily) from the fuse box to the fans and see if that stops the problem. My 2 cents…Thanks for the idea. Reminds me of My VFR that had a really poorly designed cooling system, (unlike the Concourse). It had two radiators facing sideways! The solution was to wire up a manual switch to overide the temperature sensor switch and turn on the fans whenever the meter showed anything over 190 F.
Success! Swapped out the fans from my parts bike and reinstalled the radiator. Fans came on with two bars above normal.