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post #1 of 7 (permalink) Old 04-12-2019, 04:06 PM Thread Starter
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damn_newf's Avatar
Join Date: Nov 2018
Posts: 20
Racking my brain

2000 Polaris Sportsman 500

Overheating issues

Hears what I done so far
Replaced the sensors
Replaced the thermostat ( new oem)
Flushed the system
checked the pump ( good)
Checked the cap (good)
Checked the fan(made a jumper works)

When bringin up the temp in the on the bike I used a ir heat gun to shoot the temp Straight off the thermostat housing. From what I been reading it say that the average temp is around 200ish to kick in and about 180ish to kick out.
I’m gettimg the readings at about 185 and 200 for my bike but that’s in celcuis not ferheight is this correct?

The fan now cuts in and the overheating light doesn’t come on....I’m thinking about running a deciated power line to the switch from the battery as i think the only thing I can see happening it the wires maybe getting brittle!

Opinions, ideas, advise ?

Thanks guys
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post #2 of 7 (permalink) Old 04-12-2019, 04:27 PM
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Location: Winter, Wi
Posts: 979
Are the radiator fins clear of any debree? (Mud, grass, weeds) Is air freely flowing through the radiator?


2019 Sportsman 850 SP Premium

Removed all Warning Decals
3500# Polaris Winch W/Synthetic Rope
Winch Stopper Cable Line Saver
ATV-GURU.COM Front and Rear Bumpers
2" Receiver in Front Bumper
Kenda K587 HTR Bear Claws 26X9X14 & 26X11X14
Ultimate Series Windshield Fairing, Mid & Low Height Windshield
New Style Polaris Lock & Ride Rear Storage Box
Garmin GPS176C, Ram Mount
Polaris Rear View Mirrors
4" Front Rack Extender
Center Brake/Tail Light LED
Rear LED work lights/strobes

Built on March 27 2019
Purchased New April 13 2019 0.1 Hr .2 Mi
Power Sports Abrams, Wi

2006 Sportsman 800 EFI Twin
Purchased new to me on Aug 08 2016 97Hr's 811Mi
Sold Apr 07 2019 231 Hr 3126 Mi


"I am the majority!"

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post #3 of 7 (permalink) Old 04-12-2019, 08:33 PM
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Join Date: Oct 2013
Posts: 59
That would be fahrenheit. If the light isnt coming on what makes you think its overheating??
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post #4 of 7 (permalink) Old 04-13-2019, 02:00 AM Thread Starter
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Join Date: Nov 2018
Posts: 20
FDP Rad is clear and free and going thru nicely

Johniii sometimes it kicks the light on...,since I wrote this I removed the the guts outta the old thermostat to allow constant flow and the fan kicks on more frequently now bringing the temperature up.

Im thinking I have a wiring issue/connection issue possibly
maybe the age of the wire/connectors are the issue Ill dig deeper into and see

Ill check that over today and update
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post #5 of 7 (permalink) Old 04-13-2019, 06:46 PM
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Location: Lena, IL
Posts: 3,338
The temp readings sound about right. The fan will kick on around 200 or 205 and off again below 180. If it is actually getting too hot with the guts out of the thermostat then you need to pull the radiator. Probably go the fins plugged or stuff inside so you aren't getting good circulation. What did the coolant look like when you started? Pretty green or dirty brown?

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
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post #6 of 7 (permalink) Old 04-14-2019, 05:58 AM
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Location: Illinois
Posts: 4,322
There's two separate sensors - one to turn the fan on and one to turn the hot light on - probably the light sensor is defective and turning the light on at a lower than calibrated temp.

Shop Owner and Mechanic with over 50 years experience
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post #7 of 7 (permalink) Old 04-21-2019, 05:43 AM Thread Starter
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Join Date: Nov 2018
Posts: 20
Update on the overheating issue

I replaced both sensors rad and engine ones

It seems to be kicking in and out as per proper operating temp.....thank Jebus ! Lol

Thanks everyone for all the advice and troubleshooting tip

Great site and great ppl all around

On to the next few issues lol

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