Hi, I just purchased a 96 Sportsman 500 with 702 miles on it. I drove it around for about a half hour and the overheat light came on. First problem and dont mean to sound stupid but I cant find the radiator fill cap!!! could some one tell me where it is and how to get to it as the priveous owner didnt have a manual. Second due to the temp. here in NY ( 3 Deg.) I wouldnt think it would overheat this quickly. what if any thing should I do after checking the fluid level? and is this a common problem? thanks!!

 

To access the radiator cap you will need to put the front rack off (4 screws) and then pop off the center hood cover. You will find the cap and electrical connections under there. I don't know what else to check for overheating except for any blockage of the radiator. Good luck.

 

Does your coolant resevior have any fluid in it? (opaque plastic tank, left side, underneath the fuel valve) If you are low on coolant, it does not take a long time to overheat, no matter what the temp is. The coolant resevior level is a good visual to keep track of coolant loss. If your radiator is low on coolant, the most probable causes will be either cooling hoses leaking (usually not tight enough at the clamps), or the water pump seal is leaking (right side front lower engine - where the hoses are) - although a leaking hose from the radiator to coolant resevior, busted/cracked coolant resevoir, leaking radiator, defective cooling fan, or defective thermal switch to the cooling fan all can cause loss of coolant/ overheating also.

 

Ambient temperature has little to do with these machines overheating. They will do it just as quickly with a radiator clogged with snow as one clogged with mud. If the radiator was clogged with mud in the summer, never cleaned and then driven in the winter and clogged with snow it will overheat quickly especially if the radiator is partially clogged with mud and then packed with snow. Good luck friend. they also had a factory thermostat problem. in addition to a fan control relay. clean the radiator and replace these two items and you will be trouble free. [img]i/expressions/face-icon-small-blush.gif[/img]