1994 Polaris 400l 4*4 hot light on.

[Josh Cummins]

Bought this quad a couple days ago. Got it home and couldn't get it started. Got my new starter and recoil on. Starts up great. Took it for a quick spin hot light came on. Guess my question is there a way to test the sensor? If sensor is good what would be next step? Any other common checks I should do before throwing new parts at it?

 

Thanks.

[Frank Angerano]

Welcome to Quadcrazy @Josh Cummins.
Have you noticed if the cooling fan comes on?  If not then locate the sensor on the radiator and you should find two wires going to it.  If you take those two wires off while the key or engine is ON, jump the wires  together and the cooling fan should come right on.  If so then the sensor is probably bad.  You can test it but it’s not worth it, just  replace it.  
 

If you have seen the fan running then it could be a bad thermostat or water pump. I would lean more toward a thermostat.   Make sure you order a gasket with it.  
 

If the fan is not coming on at all then there are two fuses that could stop that fan.  One is at the fuse box and the other is an in-line fusable link that’s going to the fan.   

 

 
 

[Josh Cummins]

Thanks @Frank Angerano!

I will get to checking tomorrow once I'm off from work and report back. 

[Josh Cummins]

A few things today.

 

Fan is not spinning. Will have to jump the wires. To find out more. To dark to mess with it today.

 

I did notice that while trying to put it into gear it would grind pretty bad then fall in. What should I be looking for here? I'm assuming it will be high idle but what else should I be checking?

 

Thanks again. Hopefully I'll get this thing running good before snow falls as I bought it to plow a few sidewalks.

[Frank Angerano]

If it’s idling high then yes that would be it, especially if it’s cold. Let it warm up and see where it idles. Should be around 800-1000 at best.  
 

If the fan does not come on when you jump the two wires then check for 12v on one of the wires. Either a test light or a tester/meter, one on ground and the other to any one of the two wires.  One of them should show 12v, if not then there’s a problem with power. 
if you do have 12v and the fan is not coming on when you jump the wires then the fan is prob bad OR the fan ground has failed so check that as well if the ground is good then it’s a bad fan motor. 

[Josh Cummins]

Got the fan to come on. Helps if the wires are connected. Had a break in the wire.

 

Also checked and topped off coolant. So far no hot light. 

 

Next issue to address is no AWD. Push button no light or anything. Speedo lights up but needle doesn't move. I read that on the newer quads you can bypass the Speedo to get the AWD to work. Does that apply to my 1994? 

Thanks again for the help.

New electric starts has it firing right up! 

 

 

 

[Frank Angerano]

That’s great news on the fan. As far as the awd goes its the same premise. 12v brings in the awd so take the tester and see if you have 12v on one of the wires on the push button.   If not start tracing it back to the power source, maybe a fuse.  If you do have 12v on one wire then test the other wire and press the awd button to make sure the button is working.  If it does send 12v through the button to the outgoing wire your testing then keep tracing it foreword to the controller or solenoid that brings in the awd. It will lead you to the bad or faulty part OR maybe another broken wire! 
 

[Josh Cummins]

Is the Speedo the same way or is it a cable? Cause be nice to have that working too.

 

Also do I use the demand drive or angle drive for the front hubs. I've found conflicting information on this. 

 

Thanks

[Frank Angerano]

You have to get into it and start to trace things out. Get to the back of the  Speedo and look, there should be a cable based on the year but I’m not sure unless I go through the manual.  It could be electronic also but I’m sticking with a cable.   Download the manual and start to get familiar with the machine.