I'm thinking of purchasing this model and am looking for some opinions as I know this is the first year for efi in the 500. I recall there was some issues of overheating when they first came out but other than that is there any other concerns or should I look for an 07 or newer? Another thing I'm looking for is one that will be compatable with my 04.5 SP so I can keep my glacier plow system. Thanks for your help.

 

Never heard a problem about over heating ,all Polaris did was replace the 40mm carb with a 39 mm Throttle Body a different fuel delvery system would have nothing to do with over heating

Or your talking about that melting plastic thing they had to fix. The was just a simple heatshield fix so if this ATV is used and has no melted plastic it must of been fixed aready.


There was ECM recalls but that was in 05 I think.

It should be the same as your other 4.5 Sportsman, but the EFI came with larger 26" tires,and thats the year Polaris put a tiny 4.13 gal gas tank for some crazy reason.

 

I have an 06 EFI 500. It's in the Sportsman X2 and it has been a great engine. Haven't had any overheating problems with it and it's still running great after 1500 hard miles. The X2 is a 2 seat version where there is a dump box that converts into a second seat. Another plus is that it has a 6 gallon gas tank.

 

Do you know if they put a bigger tank in subsequent years?

 

No, the last 500 efi was in 2009 now all they make is the carb H.O 500 and they all have the small 4.1 gallon tank. Your 2004 would have a larger 4.7 gal tank. Does sound like much but that a extra 15 miles of riding range.

Like mentioned the X2 version gets the 6 gal tank which should be on all the 400cc and up ATVs Polaris makes.

 

I have a 06 500 efi. The only problem I have had with mine has been the melting plastic. the motor is not overheating, it is the exhaust that gets hot, especially when using the plow, in low range.
normal riding is no problem,
the service tech told me to change the antifreeze to blue ice (i think that is what it is) and that will cool the motor down 10 degrees.
When i switch over to new antifreeze I will then put the new stuff on.

other than that i have had no problem
got about 155hours on it

Ken

 

I think Polaris offered a heat shield or heat tape for there 06 melting pastic problem.

Your BLUE ICE idea sounds like a good idea for any liquid ATV made though.

 

make sure its charging...there is a part up near the rad that have a built in rectifier and regulator that goes bad....its a $200 part....when u look at the quad put it in neutral and hold the yellow override button and then start it...the display will show what the voltage is and it should be in around 13-13.6 volts while running