I have about 25 hours on my bike and 400km and over the last few rides the heat light has came on so i stopped and waited till it went off and continued and the was getting more frequent the last ride after like 30 min it was on and then it came back on every 10 min after it went out...alll fluids are full and no mods or maintanace yet except greese....any ideas?? The very first time was when i went mud bogging and the rad was plugged and i was givener home cause i was late and it came on....(Im guessing the rad was plugged)

 

Clogged rad sounds the likely culprit. You can spray the front out but it really is built up in the back. Have went as far as pulling rad which is kind of a pia. As a min at least pull the fan/shroud assy off (4 bolts & 1 plug) & clean the heck out of it front & rear.

 

ours o.heated as well and it was a partly clogged rad. used my trail washer and cleaned it out somewhat and then cleaned it good w/ pressure washer later. no more over heating.

 

I clean mine with a pessure washer on delicate mode after every ride and it wasfairly clean last ride and it was over heating like crazy.....

 

Ahhhh... how I STILL like my crappy 'ol '07 air cooled Hawkeye!

Sorry off topic, but I just HAD to!

 

I have a 08 Sportsman 400 HO and had the same problem with mine. It was fairly new and not many hours on it. Ended up being the needle valve in the carb. We called polaris on it and they have had some issues on this. They said it may be bent a little bit or have sucked a piece of dirt into it. So we took our chances and ordered one. It fixed my problem. No more over heating. Hope this helps.

 

Should that be covered under warranty??

 

so your saying yours was running extremly lean to overheat the engine from lack of fuel?

 

Mine was covered under warranty in the end but had to push and shove to get them to cover it. We did the work ourselves. Took the carb off blew it out real good (in case it had sucked up some dirt) and put the new needle valve in. Put it back on and adjusted everything back and ran great. Polaris told us that they have had trouble with the needle valve. If it gets bent at all it will cause the thing to over heat. But then proving it's just a defect and not because of dirt was the problem. We could tell that mine was bent but there wasn't any dirt in there either that we could see. We paid for the needle valve and they just gave us our money back. But yes it did cause mine to over heat. They are also having problems with the gas gage. Mine quit working and they said it was a deffect with the way they made them. They had to put on a new tank cause they can't change out the guts of them.

 

Can someone tell me how dirt enters the fuel system and gets past the fuel filter?