03 500 Edge X
5/24/2002 build date
Which I purchased as a carry over in January of 04

I originally thought that it needed to be re-rung as per the symtoms, progressive loss of power as operating temps increased. But due to the relatively low miles I started researching other causes and came up with a 2002 TSB. (Which does include early 03 models)
SAF-02-03
consisting of
Burping the coolant system
installing a new coolant bottle (greys quickly)
setting TPS to under 4.0 volts
and installing a longer snowflap.
So with this newfound wealth of knowledge and the possiblity of getting this north star shining brightly I called my local dealer. I gave him my build date, VIN #, and TSB #. He called back later that day and said that my VIN came back as not needing this update. I then told him that I have the white coolant bottle and the same cooling system as the affected 02s. He said that if I wanted this done I would have to pay for it.
He offered me a low cost solution...
Temp sensor must be bad and suggested a temp sensor delete from SLP. Hey $8.00 bucks and that temp light never did light up....But Ive got a 500 not a 6 and DET is not available on the 5.
So back to square 1 or I guess 2 and I hate to pay for and update that I know I am intitled to.

Check out this HCS page.


Polaris Tips

Thats where I first learned of this prob.
theres also www.hardcoresledder.com-polaris-02vs03.pdf
and www.hardcoresledder.com-polaris-aug.pdf
sorry about no linkys. Not very tech savvy. :banghead:

If you take a look at October 2002 Polaris Team Tips you will see that SAF-02-03 and SAF-02-04 expired April 30, 2003.

If you have got a warped or misshaped top of the coolant bottle where the cap seats on it, You should replace it. A longer tail flap, with a backer so it does not get sucked in, can also help. Adding a cooler can also help.

Dealer stated that if the update is available to anyone who hasn't recieved it. (If your VIN # strikes as needing it.)
As I stated earlier I did not even own this machine untill 04. I was still happily zipping around on the 99 while the unfortunate 02 and 03 owners were boiling up.

Install the updated coolant bottle and the rear M10 cooler, and you wont ever have overheating issues again, within reason. The TPS on mine was at 4.25 and I never had overheating issues.