These problems have been at low speed hot light comes on resevoir on max and not spilling out and the fan is coming on.

 

Take your radiator guards off and clean them out. I had '98 that did this....the machine was spotless, or so I thought. It turns out the bottom guard for the radiator holds lots of dirt,mud or debris. When I took mine apart, I couldn't believe how much stuff was in there. I always had washed the radiator out very well from the outside. It turns out that you can't get it all unless you take it apart.

Good luck,

Rick

 

Had alot of trouble before with my 2000 500 Sportsman overheating. Had the thermal sender replaced on warranty, and now make absolutely sure the rad is clear always. My other posts on a snow guard also keep fine weeds and shtuff out of the rad. That rad must be clear, or the fan will run all day, and the coolant will not cool.

 

I HAVE DONE THAT AND STILL DOES IT , THIS HAS BEEN GOING ON FROM NEW.THANKS DAN 96 SP500

 

Maybe your thermostat isn't opening up all the way. I don't know what else to suggest. If the radiator is clean, I never knew one to run hot as long as the fan was working right.

 

I had the same problem, Polaris has a known problem with faulty oil temp sending units. Call you dealer and tell them that's what's wrong, they'll admit to it. First dealership I called, I asked if they knew anything, they claimed to know nothing about it. The 2nd dealership I called and told them I know there is a problem with the sending unit, because when I unhook it, the fan stops and light goes out. Mine was doing it from startup, cold.

 

Check this, about an inch below the neck inside your radiator on the right side as you look at it from the front of the rig is a small hole that helps bleed the system. It could be plugged or not formed right from the beginning. I use a paper clip bent just right t check. If its not made right heat the paper clip up red hot and open the hole up no larger than the size of the clip. Good luck.

 

SPORTSMANho I had the same similar problem that you are talking about with my 98 Sportsman on several occasion. Here are a few thing to try and the main one that has seemed to fix my problem is this. 1. Bypass the temp sensor in the top of the rad. and hook up a toggle switch to the fan were you can run the fan at all times. Which will not allow the rad to heat up so much if you have mud stuck in the ribbs of it that it will not get so hot that by the time the sensor cuts the fan on it is to hot for the small fan on the Sportsman to cool it back down.
2. I f you have not replaced the thermostate you might wont to do so after hooking the toggle switch up, and cleaning the radiator out.
3.burp the radiator alot of times over the course of riding you may have to add antifreeze to the bike and it can cause a air pocket which will also cause the bike to run hot.
The toggle switch was the best thing I could have ever done, and is the most important suggestion I have given you hope this helps.