3
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
3.9
GENERAL INFORMATION - COOLING SYSTEM
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION
PA-51880
Flywheel Bolt Tool
PA-49316-A
Flywheel Puller / Water Pump Drive
Nut Puller
2870975
Mity Vac® Pressure Test Tool
PA-49378
Water Pump Bearing / Seal Installer
PA-44995-A
Water Pump Mechanical Seal
Installer
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 the thermostat is
closed, it flows back to the water pump in the bypass
hose
e
.
COOLING SYSTEM 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.
1. Remove the front rack.
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.
1. Remove radiator pressure cap and test using a cap
tester (commercially available).
2. The radiator cap relief pressure is 13 lbs. Replace
cap if it does not meet this specification.
Recommended Antifreeze:
Polaris 50/50 Extended Life Antifreeze
NOTICE
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 50/50 Extended Life Antifreeze is
recommended for use in all cooling systems, and
comes pre-mixed and ready to use.
See 50/50 Extended-Life Engine Antifreeze page 2.19
for more information.
ENGINE / COOLING SYSTEM
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