First of all let me say hello Im new to this board .sevral weeks back I bought a 700 used but only 200 miles on it and right from the get go it ran hot the second time out it over heated.I took out the thermostat and but in hot water on the stove even in boiling water it bearly opend I punched out the middle of the thermostat and but it back in and I bought a new thermostat switch for the radiator it hasnt overheated sence then but after a little riding the running hot thing starts flasing then the fan kicks on.It has plenty of antfreeze in it so why Is this thing run hot.I had one guy tell me the carb needed to be rejeted any info would be a big help thank you Bill p/s other than that I love this thing

 

the intake manifold may be cracked, or the jetting may be off.
this would cuase it to run lean and very hot.

good news is if that is the problem and you fix it you will get a very noticable gain inperformance

for sealevl to about 1000feet try a 162.5 main jet.


other things to look for is to see if you cooling sytem is full of coolant, and make sure to recheck it after a ride (after is has completely cooled down)

make sure you water pump cover or water pump seal are not leaking, and if ya run in hot weather all the time, you can snip the metal arch on the thermostat and remove the guts, but keep what is left in order to create a restriction in the flow.


also, water has a higher heat transfer rate then antifreeze, but antifreeze raises the boing point of water and helps prevent corrosion., soo blend them accordingly.


there is a recall on the fan relay for the very early 2002 700s' but if you fan comes on and STAYS on then it is fine, if you fan only comes on for a split second at a time then this may be the culprit.

 

thanks polarismech where can I by the bigger carb jet thats the first thing im going to try I hope Its not the Intake.the fan relay is brand new so I dont think thats .A friend bought a 660cc he siad his ran hot the he had the carp rejeted.Again thank you,your a big help .p/a can I order a bigger jet online?

 

The first thing to check is the radiator. Cleaning it from the front is not enough. Get a hose behind the radiator and clean. You should be able to see right through it. Unless the previous owner changed the jetting, or you run at higher elevations, you shouldn't have to rejet the quad.

 

What about a higher grade gas will that make it run cooler the radiator is in great shape this bike is like brand new very clean.do they make a high output water pump for a 700? thanks again everybody Bill

 

your dealer can order jets....they are listed in the service manual.

you can buy em online but the jet manufacturers don't always use the same number system and uless you have a reference chart can be a lil tricky.


the intake manifolds go bad alot on the early ones but polaris came out with a new heavy duty replacemnet one.

the intake manifold is very easy to replace and is is probably about 50 bucks.

take the side panel off the quad as if you were changing the spark plugs, and push down on the top of the rubber intake manifold and see if it's split.

if nothing is noticeable, spray some carb cleaner or wd-40 around the manifold while it is running, and see if the engine rpms change any.
that would indicate a leak.

 

thanks again polarismech Im going to get to work on it tomarrow and check out the intake real good and get ahold of the dealer and get them bigger carb jets.Is there anything to the gas as far as a better grade gas making it run cooler.once again thank you for your time...

 

If you got a extra 60 bucks try the dyno jet kit it works great. Made bottom end more responsive and smoother more aggresive power.

 

Hey wajax where can I order a dyno jet.

 

If you are going to pull the carb anyway, you will have easy access to the carb boot. Mine was split in 3 places but not noticable on the outside of the carb.

You said one thing that concerns me. You said that the it got hot before the fan came on...

Check to make sure your coolant is flowing properly. If it is, then the fan should come on long before the hot light comes on. Also, you say the thermo was not operating properly. My guess is that ti was not working properly for the previous owner either, and he let it get to hot. I am thinking you might have blown a head gasket which pressurizes the cooling system causing the coolant not to flow properly. This may be why it is overheating before the fan kicks on.

I will let Polaris Mech take it from here. Just thought I would throw in my 2 cents