Well I finally had the time today to go thru this thing and put it all back together and after turning the idle down a few turns the beast roared back into existence lol. I took it for a ride and it is incredible how quickly it warms up and idles smooth and really feels good as new I was pleased I guess when you throw enough new parts at it you can get some good stuff lol thanks for the superior advice

 

Hopefully with all the new parts it can last a while..

 

Sure runs good now lol next step is to go thru the water pump and replace the hoses

 

If it needs a water pump seal do it right! Don't risk bending a shaft by using screw drivers,picks and pliers like some have. Most dealers will pull the seal cheap if you have the water pump cover and floorboard off. Then you don't have to buy the high $ tool for a one time use.If you bend it the whole engine has to be split to replace it.

 

I think the seal is ok but not 100% sure until I crack the cover. I'd like to check the impeller and thermostat I am not 100% sure it is moving much water except when on throttle and it really could be thermostat

 

As long as the w/p cover or drip hole isn't leaking,both radiator hoses are hot to the touch when the engine is warm,fan is kicking on and off and no hot light,I'd leave well enough alone. Normal for the coolant to circulate faster into and through the radiator as rpms go up.

 

Hot light was coming on while it sat at idle so I pulled the thermostat. Just a first guess and boiled it but it only opens about 1/4 inch after 10 min boil. No dripping from the water pump housing but hoses look sketchy. With the thermostat out I can see water moving thru the radiator.

 

You can get these every where now.NEW 1996-13 Polaris Sportsman 500 Thermostat - 3084940 | eBay Main thing is did the fan come on before the hot light. Most people think that it is always a thermostat,but a radiator sensor can get weak and not kick the fan on in time,plus a worn fan motor can pull more than 7 amps and that's usually time to replace them also. Hope it's just the thermostat.

 

Don't remember the fan kicking on can I dip the sensor and test for resistance?

 

You can test resistance when sensor is cold and then hot. Resistance should drop when hot.If resistance stays the same it's time to replace it.The sensor completes the circuit and sends power to the orange hot wire of the fan motor. Plus don't over look that voltage is going through the 10 amp fan circuit breaker under the front panel also.