Hello all. I bought a 2009 500 EFI x2 about six months ago. Recently I have been having a problem with the HOT light on my quad coming on during rides. The light comes on during all types of riding, but seems to come on more often during slow, rocky, uphill climbs.

Several times when the light has come on, the fan has not been running while other times it has. The last time it happened the fan was not running. I climbed off to see what it was doing and it looked like it was trying to run, but couldn't quite get started. I turned the quad off, turned the key back on (without starting the engine) and the fan kicked on as it should.

The dealer has had no luck in finding anything wrong with the cooling system and it is not spewing fluid when the light comes on. Any ideas? I am thinking it could be the fan motor, but the dealer will not replace it unless he sees it actually not working right. Any help would be appreciated, as I have a trail ride in Colorado the last week in August and would like to get this sorted out before then. Thanks!

 

if the fan comes on with a key cycle its not the motor... more likely a switch,ground or ecu

 

if you unhook the fan sensor on the side of the engine and then turn the key on(not start) the fan should come. it doesnt matter if its cold or hot and its a good way to check the fan. make sure there is no little rocks or wood stopping it from turning and its got a free path to turn in. also make sure the radiator is free of packed mud on both sides of it and look hard as sometimes its hard to see it. has the antifreeze ever been low where it could have sucked air into it? how long does it go beofre the light comes on? like mentioned about check all connections and put dielectric grease in them . imo

 

You may have trapped air in the cooling system due to poor dealer prep at time of sale. Elevate the front of the quad until the radiator is vertical, remove the radiator cap, start the quad and let it idle until the thermostat opens and you see coolant moving. Allow it to idle until the thermostat cycles open and closes several times. Coolant motion will stop when closed.

Keep an eye on coolant level and refill as needed, also monitor fan and verify proper operation.

Please be careful, coolant is very hot, and will burn you.

 

Thanks for the replies. I was hoping that it was just air in the system and tried that first, but the light was still coming on.

The light comes on probably after about 30 minutes of riding, give or take. The last time it came on it was only about 85 degrees outside and we were going down a fairly smooth gravel road. There should have been plenty of air going through the radiator to keep it cool.

After talking to the dealer yesterday, he is trying to make sure that everything is grounded like it should be and is also checking the switches, sensors, etc. I believe that he said he has already checked the ecu, but will ask him when they open again on Tuesday.

Thanks again for the help!

 

Shoot me a PM with your email, and I'll send you the service manual for the 08 500, which is the same as the 09, that should help you out hopefully

 

When I was having a similar problem, I used a non-contact infrared thermometer to check temperatures. They are cheap from places like Harbor freight and Northern tool and very handy to have around.

 

Thanks for the tip. I spoke to the dealer today and they are going to replace a couple of relays that might be causing the HOT light to come on even though the engine isn't actually overheating.

I have also ordered a fan switch kit and temperature gauge kit from Quadovator that I am going to try to put on tomorrow night if I get the quad out of the shop. At least then I'll know if it is actually overheating or just telling me it is. I've got to get this done before Friday, as a bunch of us are going riding in southeast Oklahoma over the weekend. That'll be a good time to test it out.