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08-24-2009, 06:19 AM
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Junior Member
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Member #1099
Join Date: Aug 2009
Location: Cental Illinois
Posts: 21
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Blown head gasket???
I believe that I blew the head gasket on my 01 Sportsman 500 HO yesterday. What all should I inspect while in the process of replacing it? I think that the damage was already done when I bought the machine, the thermostat was stuck shut, the previous owner thought that the fan was the problem.
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08-24-2009, 02:41 PM
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Polaris ATV Junkie!
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Member #858
Join Date: Jul 2009
Location: Penna
Posts: 541
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What makes you think you blew the head gasket? smoke out of the exhaust? Antifreeze in your oil???MUDDIE49? 
I'd replace the Thermostat and check the fan and sensor...before ,i'd start to pull the head off...I need more info ...
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2009 Polaris 500 HO 
Front&Rear Brush Guards
2500lb Polaris Winch
2" Ez install lift kit
26inch Zillas & 14 inch ITP wheels ..
Front &Rear Extenders
Polaris hand guards
K&N airfilter box system
My FenderGuards
EPI Clutch System
SunPro Temp gauge
Xbow Gripper mount
~DOWN&DIRTY~
Last edited by MUDDIE49; 08-24-2009 at 02:43 PM.
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08-24-2009, 05:43 PM
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Extreme ATV Enthusiast
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Member #767
Join Date: Jun 2009
Location: South Dakota
Posts: 108
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I would have to agree. More information. What does the radiator look like? is it packed with mud/grass/seeds? Did your fan kick on while riding or does it overheat quickly? The more information you throw at us, the better we are able to help you.
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08-24-2009, 05:50 PM
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Junior Member
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Member #1099
Join Date: Aug 2009
Location: Cental Illinois
Posts: 21
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The fan works and was running when the big ploom of smoke/steam that smelled very strong of antifreeze appeared. I had already taken the thermostat out and removed the guts and put the housing back in before this problem took place. I think that the damage may have already been done when I bought this machine. The guy that I bought it from had the fan hard wired b/c he thought that it was causing the overheating problem, after I rode for a little bit I decided that it was the thermostat and not the fan. I took the thermostat out and put it in boiling water and it only opened about an 1/8 of an inch.
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09-06-2009, 02:36 PM
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Junior Member
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Member #1312
Join Date: Sep 2009
Location: North TX
Posts: 6
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I just replaced a head gasket on a 98 sportsman 500, it was blowing compression into a water jacket and causing the radiator to shoot out coolant. Something you might want to check.
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09-04-2010, 07:32 AM
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Junior Member
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Member #6755
Join Date: Aug 2010
Posts: 5
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Hello. What are the torque specs for an 1997 Xpress 400 on the head gasket. And do I need any sealant on the gasket for the head at all??? Please help...
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Thanks, Becky
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