Coolant Change - Polaris 1999 Sportsman 400 Service Manual

76
2. Loosen the radiator cap (F igu re 62) to its first
detent and re lease the system pressure , then tum the
cap to its seco nd detent and remove it from the radi-
ator.
3. Check the rubber washers on the rad iator cap
(Fi gure 63) for tears or cracks. Check for a bent or
distorted cap. Raise the vacuum valve and rubber
seal and rinse the cap under warm tap water to flush
away any loose rust or dirt particles.
4 . Inspect the radiator cap nec k seat on the coo lant
tank for dents, distortion or contamination. Wipe
the sealing surface with a clea n clot h to remove any
rust or dirt.
CAUTION
Do
1101
exce ed 89 kPo (13 psi) when
p erforming Steps 4 and 5, or damage
10
the cooling system will oeew:
5. Have the radiator cap pressure-tested. The spec i-
fied radi ator cap relief pressure is 89 kPa (13 psi).
The cap must be able to susta in this pressure for 5
min utes or longer. Replace the radia tor cap if it doe s
not hold pressure.
6. Leave the radiator ca p off a nd pressure-test the
coo ling system to 69 kPa ( 10 psi). The sys te m must
be able to hold this pressure. Replace or repa ir any
co mponents that fail this test.
7. Check all coo ling sys tem hoses for dama ge or
deterioration . Replace any hose that is in question-
able condition . Make sure all hose clamps arc tight.
8. Check the radiator for leaks or other damage.
Repa ir or replace the radiator as necessary.
9. Install the front fender cover as described in
Chapter Fi ft ecn.
C oola nt C ha nge
Drain and refi ll the cooling system at the interval
listed in Tab le I.
It is sometimes necessary to dra in the coo lant
from the sys tem to perform a service procedure on
some part of the engine . If the coola nt is still in good
cond ition and
it
is not time to replace the coolant,
the coolant can be reused
if it remains clea
n. Drain
the coolant into a clean drain pan and then pour the
coolant into a clean sealable container such as a
plastic milk or bleach bottle and screw on the cap.
Only use a high-qual ity ethy lene glycol-based
coolant compounded for aluminum radiators and
engin es. Mix the coolant ,vith distilled water at a
CHAPTER T H REE
50:5 0 ratio. Coo lant capacity is listed in Ta bl e 4.
Neve r use tap or salt water, as this will damage en-
gine parts. Distill ed (o r purified) water can be pur-
chased at supermarkets.
WARNI NG
Antifreeze is an environmental toxin
and
Cal1I10t
legally be disposed of by
flushing down a drain
01'
pou ring
it
onto the ground. Place old antifreeze
into a suitable container and dispose
of it
acco rding to EPA regulations. Do
not store coo lant where it is accessi-
ble to children or animals.
WARNI NG
Do not remove the radiator fill cap
when the engine is hut. The coolant is
vel J ~ hot ami is under pressure. Severe
scalding could result ((t he coolant co-
mes in contact with skin.
CA UTION
Coolant call stain concrete and
will
damage or kill p lants. Do not drain
the coolant onto a driveway or allow
it fa drain into a planted area. Be