Well I gave up on finding the fusible link and ran hot wire from battery to relay. Now have another issue when I went to bench test the 6 month old fan--- plugged in ground connector, and ran a wire from the GREEN lead coming off of the fan plug directly to POS bat terminal and no fan. OK, so before I declare this a warranty claim, let's try running hot lead from the RED lead on fan. I touch the line to the POS batt terminal, and... 4th of July sparks. any ideas on why the shorting?? MY schematic says that the RED/GREEN leads from fan are (+)side for Hi/Lo.

The fan is a variable speed unit and should just have two connections. Power and ground. There is no "high/low". If you connected both to the battery hot side that would explain the fireworks. Fan problesm are usually associated with worn brushes although it could also be the resistor pack mounted to the ducting. If you're handy you can take the motor apart unsolder the brush connections and slip them a bit to improve contact with the armature.

Fan is only 6mo old, so wear is not an issue. Has one connector for grd and the hot side connector into the relay has TWO terminals [red & green]. I would assume that both are hot side of circuit, which is why I can't explain the sparks when I hit [+] terminal of battery with the RED fan terminal to bench test...