3
3.11
COOLING SYSTEM
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION
2870975
Mity Vac™ Pressure
Test Tool
PA-44995-A
Water Pump
Mechanical Seal Installer
PA-49378
Water Pump Bearing and Coupler
Press Tool
PA-49316
Water Pump Drive Nut / Flywheel
Puller
PA-50995
Water Pump Drive Bolt Tool
Bosch Automotive Service Solutions 1-800-345–2233
or www.polaris.service-solutions.com
COOLING SYSTEM LAYOUT AND TESTING
FLOW
Coolant is drawn into the water pump
q
, which creates
flow up through the engine to the thermostat housing
w
.
If the thermostat is open, it flows to the radiator and is
drawn back by the water pump. If it is closed, it flows
back to the water pump in the bypass hose
e
.
Cooling System Pressure Test
1. Remove the front rack.
WARNING
Never remove radiator cap when engine is warm or hot.
The cooling system is under pressure and serious
burns may result.
Allow the engine and cooling system to cool before
servicing.
2. Remove the pressure cap from the radiator and
pressure test the cooling system using a
commercially available tester.
3. The system must retain 10 psi for five minutes or
longer. If pressure loss is evident within five minutes,
check the radiator, all cooling system hoses, hose
clamps and water pump seal for leakage.
Radiator Cap Pressure Test
WARNING
Never remove radiator cap when engine is warm or hot.
The cooling system is under pressure and serious
burns may result.
Allow the engine and cooling system to cool before
servicing.
4. Remove radiator pressure cap and test using a cap
tester (commercially available).
5. The radiator cap relief pressure is 13 lbs. Replace
cap if it does not meet this specification.
Recommended Coolant
Use only high quality antifreeze/coolant mixed with
distilled water in a 50/50 ratio.
NOTE
Using tap water in the cooling system will lead to a
buildup of deposits which may restrict coolant flow and
reduce heat dissipation, resulting in possible engine
damage. Polaris Premium 50/50 Antifreeze/Coolant is
recommended for use in all cooling systems, and
comes pre-mixed and ready to use.
Polaris Premium Antifreeze
2871534 - Quart
2871323 - Gallon
COOLING SYSTEM SPECIFICATIONS
RESISTANCE READING @ IDLE
CONDITION
APPROX.
READING
(OHMS)
TEMPERA-
TURE
Engine Shut Off
70Ω± 3%
284°F (140°C)
Hot Lamp On
(engine misfire
above idle)
90Ω± 3%
266°F (130°C)
Hot Lamp
Blinking
100Ω± 3%
257°F (125°C)
Fan On 215Ω± 3%
203°F (95°C)
Fan Off 240Ω± 3%
192°F (89°C)
ENGINE / COOLING SYSTEM
To Next Page
Loading...
