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2000 Polaris Sportsman 500 Overheating

9.6K views 9 replies 5 participants last post by  dbvoytoski  
#1 ·
Quad is overheating. Last time i went hunting i saw antifreeze boiling onto the snow. I got it home. Have finally got around to trying to diagnose the problems. I have removed the radiator. Removed the thermo sensor in the radiator. Tested it for ohms at room temp and its OL then i test it in boiling water and it has resistance. I pulled water pump housing off. Crank bike for a split second and the impeller turns. The radiator fan is working because i supplied 12v to it with my power probe and it kicked on. The radiator fan doesnt seem to work though when bike runs. I have not noticed it kicking on. I have also pulled thermostat by oil filter and it does engage when in boiling water. Also i check the thermo coupler that sends the signal to the ENGINE HOT light on the dash. Im not sure if that engine light sends a signal to the fan. Im not really sure what else i could do. I dont know how to test the thermo coupler on side of motor either. If anyone could offer advice on next step I would appreaciate it.

I also connected fan and sensor up and turned quad to on position and put fan sensor in the boiling water and the fan wouldnt run.
 
#7 ·
Yes the sensor was just dirty. Now I'm troubleshooting a new issue. It has 4 x 4 and the driver front wheel won't engage. The 3 other wheels engage though. I tore hub apart and I'm thinking maybe something internal. The magnet isn't engaging maybe. I checked wires from hub. All good. Not sure what this could be that's not allowing it to engage. All hubs have fluid.
 
#8 ·
I have a 2001 500. Follow the wires from the hubs and check the connections. One of mine had come loose and caused the right front not to work. Plugged it in and works like a champ.