Dave, you’ve found out what many of us already know. There was quite a discussion about this on the old forum. DON’T hang anything from your ignition switch! Keys, knife, little flashlight, whatever, can bump the gas cap when you turn. A slight turn of the switch shuts down the secondary electrical system but the motor still runs fine. Cooling fan, lights, AWD, etc. will not function. To my knowledge all the Sportsmans do it and probably all Polarises.

I’ll bet it ran hot after 10 miles in low.


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FloodRunner, on the Wisconsin River

 

You guys are right. When I got my first Polaris (400 xplorer), the very first thing I did was get me a "cool" keychain.....wrong thing to do.....on the trail it'll rack your brain, wonderin' "What the H@ll!"....looking for everything except the key being off.
Now You Know
Todd Irvin

 

dformsto.OH YAH,been there allready.I was riding thru a mud boog one day and the AWD did'nt work.I quicklly found out that I should'nt of had such a big key chain[it hits the tank cap]I hope you did'nt hurt the engine by it overheating.BILL

 

It has happened twice now; my SP500 for no apparent reason boils over. The first time I was riding at about 5 mph in low range for about 10 miles, I stopped for a couple of minutes then it boiled over. I lost a lot of coolant but was able to continue back to camp. I returned it to my dealer for repairs the only thing he found was the overflow bottle was round due to the effect of the boiling water. The second time was 5 days ago I was not moving, the engine was running and it boiled over. After shutting the engine off and watching my coolant spray out of the overflow I realized that the cooling fan and the Hi temp light were not operating. Turning the ignition on again started the cooling fan and the Hi temp light/buzzer came on. (After this happened the first time I installed a buzzer in parallel with the Hi temp light)
My first thought was the power solenoid was faulty but I later realized it was the ignition switch. With the engine running the switch can be turned counter clockwise a 1/8" the engine remains running but the auxiliary power is shut off. This is the power that runs all the indicating lights and the cooling fan. I would suggest you all check to see if your machines are the same because the consequences could be catastrophic. Now I know the problem I continually check the key position to make sure it is perpendicular.
If yours is the same post it here for others to see.
Dave Formstone
SP500 EBS

 

We should start some kind of club, been there done that!!!!!!Stupid things not to do!!!
COB

 

Count me in that one too....1999 400 Xplorer with key chain, key gets turned partway off, 4wd, radiator fan, warning lights, no workee.

Loose the keyfob..... :-)
Todd

Here's my page
www.bluemarble.net/~kb9nvh

Check out the wreck photos in the ATV section. Hit a tree and ripped the lower a-arm off..