Have 2000 Sportsman 500 since new, K&N only acc. Meticulously maintained, but when I go, I go hard. Last service (650 miles) had stealer check my problem which has been around at least a year (100+ miles): Radiator recovery bottle boils over when it gets hot. No smoke. No anti in oil. No power loss. No overheat light, etc. Fan runs proper, except that stupid winch mount location.

Stealership "thinks" head gasket, can "check" for a little under $500. Anyone have similar problem? Does that sound like headgasket problem? Is this a difficult repair? I am decent with automotive repair and can read a repair book. Any help appreciated.

 

Try a new rad. cap first.

 

Do a combustion dye check. It will tell you if it's a gasket or crack, or something simple like a clogged radiator.

 

Thanks to both, I'll try them as soon as I get a day off.