Pointbrink,
Most of the relevant info is above on the overheating issue. As I stated above, the scenario u describe is pretty typical/common for the 2000 SP500. Your quad has two sensors related to your problem.
1) The temp switch that turns the radiator fan on/off is located on the bottom, right (passenger side), backside of the radiator. This switch is what is known to go bad on alot of our years SP500s. You tested your fan with direct power, so u know the fan is ok. So, if u start your quad up and after 10+ mins it starts to overheat (either overheat light, or puking out the overflow) without the fan ever kicking on, it's a 99.9% probability u need to replace this switch. The 0.1% chance is that the wire connector, up towards the top of the radiator, where this switch pigtail plugs into the quad's wiring harness is very corroded and just needs cleaning. Check the connector first. If that's not the issue, then that temp switch needs to be replaced.
The other sensor for temp is on the engine, right next to the upper radiator hose elbow. This switch only controls the overheat light going on/off.
As far as the front wheel bearing, yes, whomever replaced that for you is negligent. There is NO wheel bearing grease in the front bearings. You should be using Polaris Hub Oil (and only the Polaris stuff IMHO). IMHO, u need to replace the "new" bearing again. Then, after fully assembled, you fill the hub up with the Hub Oil with the fill hole at the 12 o'clock position. then, turn the wheel to the 3 o'clock position to drain the hub down to the correct fill level. replace the plug and ur done. The 4WD mechanism needs that hub oil, at the right level, to be able to engage the front wheels in 4WD.
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