Overheating Issues on an '02 800 xc

[efulton]

I have a 2002 Edge xc 800, and have done a few different mods to it:

INSTALLED LAST YEAR 2009
SLP single
V force 3 reeds
SLP high air flow kit

INSTALLED THIS YEAR 2010
SLP boost bottle
SLP cheater heads
Holtzman Tempa Flow
580 mains
.01" needle shim
911 response clutch kit

Last year, I had a temperature guage on the sled (it came on it when I bought it used) that had a yellow, orange, and red range on it. This was extremely useless. I installed a koso temp guage this year and just recently ran the sled for the first time this weekend. The sled ran at about 200 degrees F. It seemed extremely hot for a running temp. There was 6" of fresh powder, so I was getting plenty of snow on the coolers. I have also installed the additional square cooler in the back of the seat along with the longer snow flap. Last year it did overheat once in a while, but it was overheating much more this weekend. I honestly have no idea where to go from here, but I was hoping that someone on here would have some suggestions.

THANKS!!!!

 

[renotay]

My 2003 800 will run 190-210 when it gets icy on the trail, but getting into the powder usually drops it down around the 150-160 range. Overheating on the trail is pretty common for these sleds, but really rare in the powder.

Have you checked your thermostat?

 

[jgd]

x2 Yes, check the t-stat... just pull it out and run without it and see how it does. It'll take a little bit longer to warm up, so be careful.

Did this start after you made the cooling system mods? - Sounds like you may have an air bubble in the system. I would suggest taking off the filler cap and idling the sled with it off, to cycle that bubble out. Top it off as required. Also can try to jack up the nose of the sled high, take the filler cap off... wiggle the sled around to work it out. This can take awhile. The goal is to get the bubble out.... Else, this came about well after your mods; your water pump may be in need of a rebuild. jmho. Good luck!

 

[efulton]

That sounds like sound advice. The next time I go up there, I will check the thermostate and then try burping the system. I did the coolant system mods last year. This year the only mods I did were the heads, boost bottle, koso guage, and tempa flow. However, I did have to empty out the coolant system for the heads and guage, so there may be a bubble in the system. Does anyone know if there is anything aftermarket for the water pump to help combate the temperature issues? I wouldnt mind rebuilding the waterpump or getting something to help cool the system down.

Thanks!

 

[treemagnet03]

One last thing you might want to consider. This may not be important for your set-up as I can't remember the exact details, but one of the jets in the 500 range for the big blocks from those years was incorrectly labeled and was actually a 400 series bore. Caused some serious overheating/burndowns. Might want to look into that, though I know they caught that detail a few years back...just a thought. Compare the bore to some other jets to see if this is a problem for you.

Good luck!

 

[Itsflathere]

I'd look at getting a new coolant bottle too. The 2002's had cr@ppy bottles and when they were over heated they would become mishapen. They are also easy to over tightenand teh cap wopuldn't hold pressure well. As guys have said you may need to burp the system again. Raise the front end up about 2 feet or more and tilt the sled to the left a bit. That should get you enough elevation to get any bubbles out of the rear cooler and put the coolant bottle at the highest point.