My friends gf has a Polaris Sportsman(I wanna say it's a 2002 400.....maybe 500?). Everytime we go riding this thing overheats. More so while under load at slow speeds. We were driving dirt roads today and it was fine but after we hit the thicker woods to drag firewood out it started overheating. She's already had the Thermo sensor for the fan replaced, and the fan works. I checked the front of the radiator for blockage, and it looked ok. Do these machines have thermostats? Also, which hose on the radiator is the in line and which is the out line(going back to the engine)? I also checked the overflow line from the radiator cap to the reservoir, and it has a hole in it(patched it with duct tape on the trail). So we'll need to replace that. We're going to try to power flush the radiator(I work at a Ford Dealership and have access to power flushers) and check the lines.

 

i would carefully washe the radiator out. it is really hard to see when they are dirty from the back. make sure water will flow thru front to back. becare not to know bend the fins w/ the powerwasher but im sure you already know that .[img]i/expressions/face-icon-small-wink.gif[/img]