2001 Sportsman 500 HO - Polaris ATV Forum
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post #1 of 12 (permalink) Old 01-10-2017, 08:00 AM Thread Starter
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2001 Sportsman 500 HO

This is my first time posting to this forum. I have been having a problem getting my radiator fan to work. It was overheating and then I finally realized that the fan would never turn on so I thought it was the fan motor. I bypassed the heat switch on the radiator and the fan ran fine and I did not have any overheating. So that made me think that the switch is just bad. I have a new switch now and got all installed but the new switch will still not turn the fan on so I don't know what is wrong. Let me know if anyone has any ideas. Thanks!
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post #2 of 12 (permalink) Old 01-10-2017, 01:36 PM
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IIRC that machine has the fan switch in the TOP of the radiator. Unless the radiator is completely full to the top with no air trapped in it the switch has no hot water on it to make it turn on and the fan won't run. Newer models have the switch in the bottom of the radiator to prevent that occurring.
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post #3 of 12 (permalink) Old 01-10-2017, 02:01 PM
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^have seen that happen before +1 on Checking your coolant level...

Josh "FUSE"

2017 Sportsman XP LE 1000 Matte Copper
-Polaris F&R Ultimate Brush Guards, Polaris Winch

2015 Sportsman 570 SP LE Black Pearl
-Polaris F&R Brush Guards, Polaris Winch

2014 Ranger 900 XP LE Deluxe Nuclear Sunset Orange
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1989 Yamaha 350 Big Bear 4x4 - all original
Past ATV's, All Great Machines
2014 Sportsman 850 LE Pearl White
2013 RZR 800 LE Nuclear Sunset
2013 Sportsman 500 HO Bright White
-july 2014 atv of the month
2008 Sportsman 300awd LE Pearl White
1995 Xplorer 400 Green
1992 Honda Fourtrax 300 Blue
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post #4 of 12 (permalink) Old 01-11-2017, 04:36 AM Thread Starter
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It has the switch on the bottom right side of the radiator. It has coolant touching it cause if i start to loosen the switch, coolant instantly comes out.
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post #5 of 12 (permalink) Old 01-11-2017, 07:08 AM
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Did it actually overheat after installing the new switch or you just didn't notice it coming on? It takes a while to get it hot enough to cycle the fan on. Doesthe fan come on when you jumper the wires to the switch or did you just run power directly to the fan to test?

Number 3 in the pic is the circuit breaker for the fan. It's in a plastic pouch and they often get moisture inside and corrode up.

3 2201795 KIT-CIRCUT BREAKER,FAN


Last edited by polman500; 01-11-2017 at 07:13 AM.
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post #6 of 12 (permalink) Old 01-11-2017, 07:36 AM Thread Starter
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I have a temperature gun. Does anyone know the temperature that the fan should turn on and the temperature when the overheating light should turn on? I'm not sure if my light is working now.
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post #7 of 12 (permalink) Old 01-11-2017, 07:40 AM Thread Starter
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And yes I jumped right past the switch and the fan worked so all of the wiring should be fine. That circuit breaker is also okay, I checked it
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post #8 of 12 (permalink) Old 01-11-2017, 07:48 AM
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On the newer machines I think its like 204 degrees or something like that. Not 100% sure though

Josh "FUSE"

2017 Sportsman XP LE 1000 Matte Copper
-Polaris F&R Ultimate Brush Guards, Polaris Winch

2015 Sportsman 570 SP LE Black Pearl
-Polaris F&R Brush Guards, Polaris Winch

2014 Ranger 900 XP LE Deluxe Nuclear Sunset Orange
-Lots of Mods/Accessories

1989 Yamaha 350 Big Bear 4x4 - all original
Past ATV's, All Great Machines
2014 Sportsman 850 LE Pearl White
2013 RZR 800 LE Nuclear Sunset
2013 Sportsman 500 HO Bright White
-july 2014 atv of the month
2008 Sportsman 300awd LE Pearl White
1995 Xplorer 400 Green
1992 Honda Fourtrax 300 Blue
1986 Yamaha Moto4 225 Blue
1986 Honda Fourtrax 350 Red
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post #9 of 12 (permalink) Old 01-12-2017, 10:35 AM Thread Starter
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I'm stuck! I have checked the fan, the fan switch, the hoses, the coolant level, the empeller on the pump, the thermostat, everything seems to be working out of all those. Any ideas what could be causing it to over heat still?
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post #10 of 12 (permalink) Old 01-12-2017, 04:43 PM
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fan off-165 deg. +-8
fan on-185+- 7
temp. light on at 220 deg.
The connector up by the right frame rail that you hook the fan switch is kinda prone to getting built up with dirt through years of use. This should be where you hook your jumper wire to ,so that the fan will come on as soon as you turn the key to the on-run position.Remove the terminals from the connector and make them clean enough to eat off of, then reinstall.
The 500 is known for getting air pockets in the block. You'll need to jack the front-end wayyyy up and start and fill radiator and resevoir ,revving the engine occassionally, sometimes removing the thermostat housing and fiiling the jug with a water bottle helps, then reinstall housing , fill radiator as needed. See, the water pump impeller just can't pump air.

'03 Sportsman 500ho
'14 Massimo 800
'08 Hisun 700(gone)
'02 expedition 425(gone, but missed)
'98 Sport 400 (gone)
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