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2005 Switchback 800 Overheating
- Overheating in light snow conditions, Need help installing additional radiator. Need suggestions
started by Matt800
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October 12th 2009 at 8:56 AM
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Matt800
Starting Member
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10 Posts
Group: Members
Member Since: October 12th 2009
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My 2005 Switchback 800 overheated last winter (2008-2009). The waterpump impellar was replaced (it spun), the temp sensor was replaced, the cooling system was flushed, and the inner and outer head gaskets were replaced. The heat exchange and radiator are in the rear, up high, and are designed so that if there is light snow conditions, it overheats.
I don't want to add ICE SCRAPERS and lose reverse. I don't want to invest in the Slide Kicks reversable ice scrapers either. What I would like to do is add a small radiator and splice it into the current cooling system. Has anyone done this? Are there are any kits, instructions, ect? Pictures would be very helpful too. Any other suggestion are welcome.
Thank you,
Matt
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Site Supporter
Group: Site Supporters
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October 12th 2009 at 8:59 AM
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slamdry
President of the EFP/BRP/SLEDCRUSHER fan club!!
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2397 Posts 
Group: Members
Member Since: February 17th 2007
Location: Cohoes, NY, USA
Current Sled: 02 RMK 600 + 97 xc 600
2008-2009 Miles: 910
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you dont loose reverse with ice scrapers, you just need to remember to clip them up before going backwards.
Quote originally posted by BRP-4-LIFE If I don't keep this sled for the whole season, I promise to never sign on to Snowmobile Fanatics again.
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October 12th 2009 at 9:28 AM
[ Modified October 12th 2009 at 9:34 AM
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Rock
raise a little hell
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1195 Posts 
Group: Members
Member Since: June 14th 2006
Location: St.Paul Park, MN, USA
Current Sled: 2005 700xcsp
2008-2009 Miles: 571
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Hi-Performance Engineering, Inc
Adding HPE’s radiator kit to a Polaris EDGE chassis increases the sled’s cooling capacity in marginal snow. (Image courtesy of Hi-Performance Engineering)
Although owner Glen Follet has a strong Arctic Cat heritage, his company, Hi-Performance Engineering, caters to Polaris enthusiasts with a line of special Polaris kits. If you are looking to upgrade an older Polaris Indy chassis, you’ll find that HPE offers an aluminum radiator kit to fit the EDGE.
This radiator kit is designed to increase the sled’s cooling capacity, making it perfect for use on ice or in limited snow conditions when snow isn’t getting to the sled’s runningboard-mounted heat exchangers. This kit can be a real benefit for hot-running, high performance trail sleds. The HPE kit includes a custom built radiator, hose, mounting hardware and comes with easy-to-follow installation Instructions. The kit retails for US$274.95.
Boondockers will appreciate the snow blocking action of HPE’s Powder Snow Pre-Filter Kit that’s designed for the Polaris IQ Switchback and newer RMK models. HPE states that while the kit increases intake surface area for increased performance, it also eliminates the stock Polaris foam filters.
The pre-filter securely fastens to the hood, providing a more positive seal for improved cold air intake with less chance of snow ingestion through intake vents. Featuring a brushed aluminum grate and pre-filter material that repels snow and water, the HPE Powder Snow Pre-Filter Kit retails for US$41.95.
Another airflow kit is HPE’s Polaris High Flow Intake Kit that converts the top of the sled’s airbox to increase intake air velocity. Engineered to push more air volume into the airbox, the design is claimed to improve atomization efficiency of fuel, thus improving throttle response and delivering as much as an additional three horsepower peak. The kit retails for US$42.95
For more information, contact:
Hi-Performance Engineering
PO Box 482-823
Lowell Drive
Thief River Falls MN 56701
Telephone: Order Department, (800) 451-5268
Technical or Product Information: (218) 681-2390
Web: http://www.hiperf.com/
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October 12th 2009 at 10:06 AM
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Matt800
Starting Member
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10 Posts
Group: Members
Member Since: October 12th 2009
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Thank you. I will check that out. It could be exactly what I need.
Quote originally posted by Rock
Hi-Performance Engineering, Inc
Adding HPE’s radiator kit to a Polaris EDGE chassis increases the sled’s cooling capacity in marginal snow. (Image courtesy of Hi-Performance Engineering)
Although owner Glen Follet has a strong Arctic Cat heritage, his company, Hi-Performance Engineering, caters to Polaris enthusiasts with a line of special Polaris kits. If you are looking to upgrade an older Polaris Indy chassis, you’ll find that HPE offers an aluminum radiator kit to fit the EDGE.
This radiator kit is designed to increase the sled’s cooling capacity, making it perfect for use on ice or in limited snow conditions when snow isn’t getting to the sled’s runningboard-mounted heat exchangers. This kit can be a real benefit for hot-running, high performance trail sleds. The HPE kit includes a custom built radiator, hose, mounting hardware and comes with easy-to-follow installation Instructions. The kit retails for US$274.95.
Boondockers will appreciate the snow blocking action of HPE’s Powder Snow Pre-Filter Kit that’s designed for the Polaris IQ Switchback and newer RMK models. HPE states that while the kit increases intake surface area for increased performance, it also eliminates the stock Polaris foam filters.
The pre-filter securely fastens to the hood, providing a more positive seal for improved cold air intake with less chance of snow ingestion through intake vents. Featuring a brushed aluminum grate and pre-filter material that repels snow and water, the HPE Powder Snow Pre-Filter Kit retails for US$41.95.
Another airflow kit is HPE’s Polaris High Flow Intake Kit that converts the top of the sled’s airbox to increase intake air velocity. Engineered to push more air volume into the airbox, the design is claimed to improve atomization efficiency of fuel, thus improving throttle response and delivering as much as an additional three horsepower peak. The kit retails for US$42.95
For more information, contact:
Hi-Performance Engineering
PO Box 482-823
Lowell Drive
Thief River Falls MN 56701
Telephone: Order Department, (800) 451-5268
Technical or Product Information: (218) 681-2390
Web: http://www.hiperf.com/
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October 12th 2009 at 10:42 AM
[ Modified October 12th 2009 at 10:45 AM
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Matt800
Starting Member
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10 Posts
Group: Members
Member Since: October 12th 2009
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Bummer. I contacted HPE and spoke to the engineer who told me that Radiator Kit was discontinued because there were no buyers. Do you know of any other manufacturers of similar kits???
Quote originally posted by Matt800
Thank you. I will check that out. It could be exactly what I need.
Quote originally posted by Rock
Hi-Performance Engineering, Inc
Adding HPE’s radiator kit to a Polaris EDGE chassis increases the sled’s cooling capacity in marginal snow. (Image courtesy of Hi-Performance Engineering)
Although owner Glen Follet has a strong Arctic Cat heritage, his company, Hi-Performance Engineering, caters to Polaris enthusiasts with a line of special Polaris kits. If you are looking to upgrade an older Polaris Indy chassis, you’ll find that HPE offers an aluminum radiator kit to fit the EDGE.
This radiator kit is designed to increase the sled’s cooling capacity, making it perfect for use on ice or in limited snow conditions when snow isn’t getting to the sled’s runningboard-mounted heat exchangers. This kit can be a real benefit for hot-running, high performance trail sleds. The HPE kit includes a custom built radiator, hose, mounting hardware and comes with easy-to-follow installation Instructions. The kit retails for US$274.95.
Boondockers will appreciate the snow blocking action of HPE’s Powder Snow Pre-Filter Kit that’s designed for the Polaris IQ Switchback and newer RMK models. HPE states that while the kit increases intake surface area for increased performance, it also eliminates the stock Polaris foam filters.
The pre-filter securely fastens to the hood, providing a more positive seal for improved cold air intake with less chance of snow ingestion through intake vents. Featuring a brushed aluminum grate and pre-filter material that repels snow and water, the HPE Powder Snow Pre-Filter Kit retails for US$41.95.
Another airflow kit is HPE’s Polaris High Flow Intake Kit that converts the top of the sled’s airbox to increase intake air velocity. Engineered to push more air volume into the airbox, the design is claimed to improve atomization efficiency of fuel, thus improving throttle response and delivering as much as an additional three horsepower peak. The kit retails for US$42.95
For more information, contact:
Hi-Performance Engineering
PO Box 482-823
Lowell Drive
Thief River Falls MN 56701
Telephone: Order Department, (800) 451-5268
Technical or Product Information: (218) 681-2390
Web: http://www.hiperf.com/
High Performance Engineering doesn't make that Radiator Kit anymore. The part was discontinued due to a lack of need/sales. Any other manufacturers of Radiator Kits that fit the Edge Chassie? I don't know where to look from here.
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October 15th 2009 at 11:36 AM
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Matt800
Starting Member
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10 Posts
Group: Members
Member Since: October 12th 2009
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I scratched the radiator kit idea. There is a much easier way which is by adding the Auxiliary Cooler made by Polaris to fit all Edge chassis. Too bad my local dealer didn't know about it....really too bad because it's a Polaris part. Appearantly, they thought I was the only one in the world having this overheating problem with my 2005 Switchback 800.
Anyways, I ordered the Polaris Kit # 2202373 which was the latest part # for the cooler kit that fits all Edge chassis. The old part # was 2202143 (something must have been changed from the original kit). It cost $117 including tax which is great and will be an inexpensive solution to prevent overheating in icey and low snow conditions.
My one worry is that my long pics are going to hit it when landing hard. I have the tunnel protectors on there now and I guess the new cooler will fit between them. I just hope the cooler isn't lower than the protector rails. I will stiffen up the rear suspension too. The dealer I ordered it from said a guy bolted on a pair of those plastic track slides ($15) on the back half of the tunnel protectors to add more depth to avoid the pics from hitting the cooler. Won't know how it goes for a couple months. Hope this info helps anyone who has the Edge chassis and who has overheating issues.
- Good Riding
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October 15th 2009 at 12:50 PM
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Rock
raise a little hell
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1195 Posts
Group: Members
Member Since: June 14th 2006
Location: St.Paul Park, MN, USA
Current Sled: 2005 700xcsp
2008-2009 Miles: 571
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Glad I was able to help you out 
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October 24th 2009 at 7:22 PM
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Matt800
Starting Member
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10 Posts
Group: Members
Member Since: October 12th 2009
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Tried installing the kit this weekend. It only fits traditional Edge Chassis and not the extended track, length 144. The coolers on my sled run up the foot rails and loop around way up high though the rear cooler which is small and has fins for heat disbursement. They changed the design after 2005. Returned the kit and waiting to hear from dealer. So much for me easy fix. Nothing is ever easy. I just hope they made a kit for the 2005 Switchback 800. I am guessing but they probably only sold 1,000 of these sleds and only 1/2 of them had an overheating issue, so Polaris probably didn't make any changes to the original cooler. We'll see. Quote originally posted by Rock
Glad I was able to help you out
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October 24th 2009 at 7:43 PM
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Rock
raise a little hell
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1195 Posts
Group: Members
Member Since: June 14th 2006
Location: St.Paul Park, MN, USA
Current Sled: 2005 700xcsp
2008-2009 Miles: 571
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Well that suck's.......I would buy the heater core fore a car and modify it to fit in the nose cone. I know it has been done buy a few people and works great.
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October 24th 2009 at 10:20 PM
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MX86
Powder Rider
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1640 Posts
Group: Members
Member Since: March 1st 2007
Location: Nashwauk, Minnesota, USA
Current Sled: 1999 polaris 700 SKS mod
2008-2009 Miles: not enough
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okay so let me get this straight, you don't wanna invest in reverse scratchers, but will invest a few hundred dollars over the cost of the scratchers for a additional cooler?
2006 Yamaha YZ250
KYB SSS Suspension w/ Race Tech G2 gold Valve, ASV F3 levers, Tag Metals Triple clamp w/Pro Taper Bars, IMS Pro Series Pegs, Motion Pro Twist Throttle Assembly, VF3 Reeds
Thanks to my newest 09 Sponsors:
Gravity Worx Racing
Duner Central
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October 29th 2009 at 12:24 PM
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Matt800
Starting Member
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10 Posts
Group: Members
Member Since: October 12th 2009
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Spoke with another mechanic at a second Polaris dealer who said to avoid costly and time consuming additions to lower the temp. and try the snow and ice scratchers first. I'm buying the RSI track rail mounted, solid scratchers, not the Slidekicks and not the ski mounted. Everyone has said they work great and lower the temp significantly. And if that doesn't work, I'll sell it and buy a newer sled.
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