Help with 1999 sportsman 500 overheating

Here is the history leading up to the question:

2 or 3 years ago I had the water pump redone at a dealership. I also replaced the thermostat with a 'lower temp' model off of ebay (big mistake) because I was over heating.

Next few rides I had no problems (I only get to go 2 times a year usually)

This past spring while at Hatfield McCoy on Day 2 of riding hard it started to over heat after long higher speed runs or a long hill climb. My assumption is that the coolant was not able to get cooled sufficiently before the thermo was opening causing the overheats.

Fast forward to last week when I finally get to working on this.

Step 1, replace thermo with OEM new.

Step 2 Drain coolant and refill with distilled water (3 times to flush all coolant out)

Step 3 drain water our and add Engine Ice blue coolant. (Supposed to help reduce temps)

Step 4 drive around the yard and get it warmed up until the fan kicks on ( a few times ) no issues. No over heats, fan working as it should.

Step 5 drain all this coolant and pull thermo hose off to drain everything off. I wanted to make sure I got all the water diluted engine ice out so I have a good mix in,

Step 6 refill with engine ice, warm up and top off with radiator cap off. replace cap and ride for a few minutes.

This brings me to my problem.

NOW the overheat light comes on after riding a little bit. At about the 20 second mark of idling with the overheat light on, the fan finally kicks on and cools it off and light goes off. It is overheating BEFORE the fan kicks on.


What did I miss? Is there a different possible bad part that I missed?

Thoughts?

Anyone in canada wants to buy isoflex grease with me?

I am buying a tube of isoflex for my clutch, but I don't really need 50 grams of the stuff, and it's quite expensive to get.
If 1 or 2 other guys want to get in the deal, I can order a tube and split it in syringes and just ship to you, that way we would all save.

I'm getting the lastest info from the reseller for prices and I can give more specific prices when I have them, but it's quite obvious that we would save if we split a tube for 2-3 guys...

If we have lots of people, they sell 400 gram tubes that could be split into 16x25 grams, but I need 16 guys to do it so it's worth it.... or 8x50 grams, whatever.

Anyone wants to list their names as interested in an isoflex deal?

Canada only

Thanks

Can Am Defender HD8 and HD10 motor the same

Maybe this question has been asked but I searched and I couldn't find it. I currently have a Polaris ranger 900 and am considering switching to a Defender. Soooo my question is.... Is the motor in the HD8 and the HD10 the same motor? Is the HD10 motor just pumped up to give it the additional HP??? I have been told by the dealer both ways yes and no...…???? Thanks in advance.

97 Sportsman – Hub Drain Plug Problem

Good morning everyone,
Last night after work I was going to change the fluid in the hubs. The sportsman would grab hard to the right at times and I read where it may be caused by lack or no fluid in the hub assembly.
Took the right hub cap off and there was no fluid in the hub. When I went to look at the hub drain plug to identify which torque bit I would need I found it had been damaged, please see the photos. I cleaned it out as best as possible and attempted to fit a torque bit in but no luck each one spun out and I didn't want to damage it any further so I pulled the hub cap off and added a little bit of fluid that way.
The other side is just as badly damaged, so I ordered two new oem hub drain plugs this morning.

My question is, how can I get the old ones out? I tried heat but was worried about getting the hub too hot and possibly damaging an interior component. I tried to tap in the torque bits but they just spun. There is not enough material above the hub to catch onto with a vice grips to turn. Looks like either I will need to tap them with a chisel or drill them and use an EZ Out tool to help break them free.

Any other suggestions for this situation?

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