Cooling System Pressure Test; Coolant Air Bleeding Procedure - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

Cooling System Pressure Test

WARNING
Never remove filler 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.
System Pressure Test
1. Remove radiator cap cover located under the
storage box access panel. See Chapter 5.
2. Remove recovery bottle hose from coolant filler.
3. Connect a Mity Vac™ (PN 2870975) to radiator and
pressurize system to 10 PSI (68.9 kpa). The system
must retain 10 lbs of pressure for five minutes or
longer. If pressure loss is evident within five minutes,
check radiator, all cooling system hoses and clamps,
or water pump seal.
Filler Cap Pressure Test
4. Remove filler cap and test cap using a commercially
available cap tester.
5. The filler cap relief pressure is 13 psi. Replace cap if
it does not meet this specification.

Coolant Air Bleeding Procedure

Use this procedure when a unit overheats and no
apparent leaks in the cooling system are found.
NOTE: If the coolant level is LOW in the radiator, or
if there are leaks in the system, the coolant system
will not draw coolant from the reservoir tank.
1. Park machine on a flat surface. Remove filler cap
2. Stop the engine and let cool for a few minutes or until
3. Repeat Steps 1 and 2 until no more coolant is pulled
4. To test, install the radiator cap and idle machine until
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
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and top off coolant. With the cap removed, start and
idle machine for 5-10 minutes until steam is visible in
the filler neck area.
an air bubble is seen at the filler neck, or there is a
dropping of the coolant level indicating that coolant
has been pulled into the system.
NOTE: Slowly squeezing the filler neck/coolant
return hoses will aid in purging the system of air.
Pump the hose using your hand several times.
Elevating the rear of the ATV with a floor jack
(rear tires 4-6", off the ground) also aids the
purging of air from the system.
into the system.
fan comes on. Make sure the fan comes on before
the hot light.
ENGINE
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