I have a '99 Sportsman 500 and the radiator tank on the top seems to be leaking around the left hose. I tightened the hose clamp thinking it was just loose but it is still leaking antifreeze. I think the outlet tube is cracked. Has anyone else had this problem? I have a '00 parts manual but the radiator for a '00 looks different from mine. Was there a design change from '99 to '00?
Thanks for any help.
Gsport500

 

Gsport500,I have a "99" Sportsman 500 and had the same thing happen to me. On mine it was the radiator hose that was leaking right at the clamping point. Cut about 1/4 inch off the end of the hose and it was fine for awhile then it started leaking again. Put a new hose on it. Hasn't leak since.
Could be that the hose was too short in length and the flexing of the motor and frame caused a small hole to come in it.?? I to thought it might be the radiator neck leaking, but when I cut the hose and tighting it back up it didn't leak for a while.

OH, I was going to buy the replacement hose for about $12.00. Went to NAPA auto parts and bought a Gates 3/4 inch heater hose for under $2.00. The bottom radiator hose I will have to buy the replacement because of the pre-formed hose. The top has only a slight bend in it.

 

If it's not the hose, it could be the resavoir where it's crimped. Mine leaks, and I tried to have it recrimped by a radiator shop with no luck. Mine is a slow leak, I can ride all day in hot weather and only have to add a little.

In '00 (most anyway) Polaris went to really nice all aluminum radiators---no plastic, and one piece nothing crimped. I like them, but they cost too much to upgrade for me.

 

Thanks for the info guys. I hope to get it apart next weekend and see what the problem is.

Gsport500