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Discussion Starter · #1 ·
Took my 2012 Polaris Sportsman 500 out of the storage shed (worked perfectly when put in the shed last fall), put a new battery in, and took it for a quick spin. About ¼ mile out, the HOT indicator starts flashing. I get back home and the engine isn’t even hot to the touch yet. The oil filter was barely warm. I gave it a good bath, making sure the radiator was clean, HOT light still comes on after ¼ mile. One thing I did notice is that the AWD Indicator is also coming on, but I am in 2WD. Antifreeze in the radiator and the overflow looks brand new.
I don’t know where to start looking and I don’t want to randomly start replacing parts. Can anyone give me some suggestions?
 

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2008 800 ho efi, 2019 850 SP premium
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Your question has now been logged into the queue and the next available forum member will answer you shortly. You will be given more advice than you could hope for.

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Is the coolant circulating? The 500 is known for the plastic water pump impeller slipping on the shaft.
 

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Discussion Starter · #4 ·
Is the coolant circulating? The 500 is known for the plastic water pump impeller slipping on the shaft.
Thank you. I will check. I don't think it ever gets hot enough to open the thermostat.
 

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Carb or EFI model? They are wired differently
 

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97 Polaris 500 sportsman 4x4 Indepedent shaft drive, 2000 Honda 450S foreman
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Hello everyone im new to forum but have a 97 500 sportsman 4x4, P/O NEVER cleaned the exterior of radiator nor was the cooling system functioning because of the rad being packed with dirt, and fan not functioning. Anyway all that is fixed, I used water wetter in my rad and wired fan back up, also added a flush tee/bleeder inline…problem never returned , hope this might help someone in future
 

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Hot light has a separate sensor from the fan - I propose the hot sensor failed
153292


AWD is trickier - when the AWD switch is on, 12v is connected to the grey wire - the grey wires go to the Hilliard Clutch magnet coil - the coil is grounded through the speedo - you may have multiple connection problems where as the speedo lost ground and is trying to ground through another circuit - I recommend you check all the ground connections first (loosen them, clean them, dielectric grease them and tighten them both ends of frame, engine and battery connections - then unplug and reconnect all the electrical connectors filling them with dielectric grease while you are in the process.

See what the result is
 

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97 Polaris 500 sportsman 4x4 Indepedent shaft drive, 2000 Honda 450S foreman
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Mine the P/O had really neglected, out of lack of knowledge just about everything on it,luckily it never seen a trail, only plowed a driveway. I have Demand Drive and I just refilled the hubs, the gearcase is same , magnetic and the guy randomly stuck a wire to hot that should have been ground, im currently working on that too. I actually need a speedo for mine as the bike will never truly function fully to my limited knowledge bc the relays n indicator lights among other things are in the speedometer, found 1 on ebay OEM for 149$ is fhis good price?
 

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............ speedometer, found 1 on ebay OEM for 149$ is fhis good price?
The same unit was used on the following models and has an MSRP of $425 - so if it works, $150 is a bargain

2010 SPORTSMAN TOURING 500 HO (A10DH50AX/AZ) - Electrical, Gauges & Indicators
2011 HAWKEYE 400 HO 2X4 (A11MB46FZ) - Electrical, Gauges & Indicators
2011 SPORTSMAN 400 HO 4X4 (A11MH46AX/AZ) - Electrical, Gauges & Indicators
2011 SPORTSMAN 500 HO (A11MH50AX/AZ) - Electrical, Gauges & Indicators
2011 SPORTSMAN 800 EFI (A11MH76AX/AZ) - Electrical, Gauges & Indicators
2011 SPORTSMAN TOURING 500 HO (A11DH50AX/AZ) - Electrical, Gauges & Indicators
2012 HAWKEYE 400 HO 2X4 (A12MB46FZ) - Electrical, Gauges & Indicators
2012 SPORTSMAN 400 HO 4X4 (A12MH46AF/AX/AZ) - Electrical, Gauges & Indicators
2012 SPORTSMAN 500 HO (A12MH50AD/AO/AQ/AX/AZ) - Electrical, Gauges & Indicators
2012 SPORTSMAN 800 EFI (A12MH76AD/AX/AZ) - Electrical, Gauges & Indicators
2012 SPORTSMAN FOREST 800 (A12MH76FF) - Electrical, Gauges & Indicators
2012 SPORTSMAN TOURING 500 HO (A12DH50AX/AZ) - Electrical, Gauges & Indicators
 

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97 Polaris 500 sportsman 4x4 Indepedent shaft drive, 2000 Honda 450S foreman
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Yea i saw that, lol thanks. You guys have some serious knowledge on these guys i was trying to get on forum for awhile, glad i did. Love learning new stuff about them anyway…im pretty sure that not all the functions will work properly without the speedo connected like 4wd etc not sure u can even use override to counter…I know there’s a jumper method but like on a steam boilers limits n safeties I don’t override a safety that’s meant to save your life and the life of the machine
 

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Discussion Starter · #13 ·
Hot light has a separate sensor from the fan - I propose the hot sensor failed
View attachment 153292

AWD is trickier - when the AWD switch is on, 12v is connected to the grey wire - the grey wires go to the Hilliard Clutch magnet coil - the coil is grounded through the speedo - you may have multiple connection problems where as the speedo lost ground and is trying to ground through another circuit - I recommend you check all the ground connections first (loosen them, clean them, dielectric grease them and tighten them both ends of frame, engine and battery connections - then unplug and reconnect all the electrical connectors filling them with dielectric grease while you are in the process.

See what the result is
Thanks very much for the help!
 
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