We just bought 2 new 06 500 EFI's to replace our trailboss 330's that we had. I love the sportsman, but after less than 200 miles the plastic on the side by the exhaust has melted holes through it form the exhaust heat, not just on one of the new ones but both of them. Dealer is replacing it under warranty, but I was just curious if this has been a problem with the 06 model. There have been a few small problems with them but the plastic problem kinda concerns me.

 

800 miles on mine and no melting plastic.[img]i/expressions/face-icon-small-smile.gif[/img]

 

hey speedy, is your fan cycling properly?

 

I think that its the fan sensor myself on one of the quads, but you know how dealers are, they reset the computer and said it was fine. My quad the fan cycles as its supposed to and its stil melting, my wifes it will come up with a hot light after about 5 miles of riding and after cycling the key a few times it will go off and the fan will run as its supposed to. We just took them out again yesterday for another 20 miles or so and hers was still not cycling properly and I just picked them back up at the dealer as they said that they were all fixed. Kind of disappointing after paying that much for the things and the service that we get sucks.

 

"SUBJECT: 2006 Sportsman 500 EFI Erratic Cooling Fan / ‘HOT’ Lamp Operation

PURPOSE:
Polaris has determined the 2006 Sportsman 500 EFIs listed above may encounter erratic fan operation in conjuction with a ‘HOT’ lamp
that illuminates excessively or when engine temperature is not sufficient to activate the ‘HOT’ lamp. Cooling fan start-up has been
identified as adversely affecting other cooling system controls. A Resistor Harness Kit, PN 2203193, has been created to resolve this
issue."


Have your dealer do this fix. He should have a notice from Polaris to do this as they come out of the crate, but the early ones do not have this. so if you have a early one get it checked. It is a very simple fix.

 

Thanks for that information. My quad has a build date of 11-05 and my wifes is 06-05. Mine hasn't done that yet but it sounds exactly like what is happening to hers. I printed that and will take it to the clueless dealer when I take the quads back in for the new plastics.
Again thanks.

 

another clueless dealer, there needs to be some sort or regulatory organization that these dealers have to answer to, this is a serious problem with Polaris and they are partly to blame, they let anyone and thier mother sell these things. anyway, hope it works out speedy!

 

After talking with the dealer yesterday, he looked it up and my wifes quad si on the list of serial numbers to have the resistor fix. He said he ordered the parts. It kinda is a scary thought that I had to learn about this from this forum, and not the service department that I should trust my quad with. Thanks for the information though.

 

Our service manager is on top of everything. He has known about this issues since Sept, I think I remember him saying something about this right after they annouced the new 500EFI, But we have just sold the first 500EFI(we had lots of left over 05 from our stores in Iowa, they shifted into snowmobile sales early and shiped alot of their atvs to us) I do not know how he does it but he knows about stuff before Polaris even puts it on the Dealer site. I guess he knows someone highier on the ladder.