3.41
Engine/Cooling/Exhaust
3
COOLING SYSTEM
Thermostat Replacement
1. Remove the housing cover, by removing the cover
bolts.
2. Check the gasket condition and replace if damaged.
3. Replace the thermostat. Make sure that the spring
side
is facing downward or toward the engine.
4. Replace cover. Torque the cover fasteners to
spec
ification.
5. Verify the bleed screw and washer are installed.
Thermostat Orientation
The thermostat must be installed in the cylinder head as
shown in the illustrations.
Center Thermostat Location
Offset Thermostat Location
800 Thermostats
There are two different thermostats used depending on
what model the engine is installed in.
Both thermostats are full open at 120
F (49C).
Allow engine to cool completely before working with the
engine cooling system.
Engine coolant can be under pressure and hot.
Esca
ping steam and/or coolant may cause severe
burns to exposed skin.
Cover Fasteners: 9 ft-lbs (12 Nm)
BLEED SCREW
WASHER
HOUSING COVER
THERMOSTAT
GASKET
Cooling System Type Thermostat PN Bleed Hole ID
RUSH/Switchback 7052433 2 mm
SB Assault/RMK
PRO RMK/
RMK Assault
7052452 3.5 mm
BRIDGE ALIGNED WITH HOLES
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