Over Heating - Polaris RZR XP Service Manual

OVER HEATING

1. Check cooling system using combustion leak tester
for any combustion gasses entering the cooling
system. Adding coolant before test may dilute the
system and cause inaccurate test results.
2. Verify coolant is filled to correct level. Refer to
Coolant Level Inspection page 2.36.
• If coolant is low, fill to correct level.
3. Test and check for correct coolant mixture. Refer to
Coolant Strength page 2.36.
• If coolant mix is incorrect, correct mixture as
necessary.
• If incorrect coolant was used in vehicle, flush cooling
system and bleed, fill to correct level, and recheck.
4. Check Radiator and cooling fans for restrictions or
damage
• Check for debris, dirt, or mud between fan and
radiator restricting air flow. If present, clean and
recheck.
• Check for damage to radiator or cooling fans. If
damage is found to components repair or replace
as necessary.
• Inspect for any aftermarket modifications that may
be restricting air flow. (Radiator Modifications, Grille
Modifications, Aftermarket Bumpers, Lightbars,
etc.) Pay close attention to the Radiator Shroud
presence and placement.
5. Check for coolant leaks / air pockets.
• Visually check all hoses and radiator for leaks. If
leaks are found repair as necessary.
• Check cooling system using coolant pressure
tester if leaks can not be seen on visual inspection,
refer to Engine / Cooling system — Cooling System
Pressure Test page 3.34.
• Check for air in cooling system. Refer to Cooling
System Bleeding page 2.39.
6. Check Oil level.
• Low oil level or oil in need of changing could cause
engine temp to increase.
• Check level and correct as necessary. Check
maintenance history to determine if oil need to be
changed.
7. Check Cooling Fan operation.
9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual
© Copyright Polaris Industries Inc.
• Make sure the cooling fan is engaging. Command
cooling fans on and off using Digital Wrench to
check operation.
• Monitor engine temp using Digital Wrench or
temperature gun reading off a radiator hose. Once
engine has reached running temperature cooling
fan should engage.
8. Water Pump / Thermostat / Radiator may be suspect
of concern.
• Thermostat could be opening too slowly or stuck
closed. Check temp using temp gun on inlet and
outlet of thermostat to check for correct operation.
Temperature should read similar on both sides if
operating correctly.
• Water pump may be faulty or not circulating
enough coolant to keep temp down.
• Radiator core may not be functioning correctly or
failed causing concern. Using temp gun check inlet
and outlet temperature. If considerable temp drop
is not seen, suspect radiator failure. Refer to
COOLING SYSTEM.
9. Faulty Temp Sensor / Circuit / ECU.
• Confirm engine is overheating. Run vehicle and
monitor coolant temp using temp gun on radiator
hose. If engine does not actually overheat but
shows on display, suspect sensor or circuit.
• Check connections at temp sensor and wiring. If
damage is found repair, as needed.
• Resistance test sensor, refer to Electrical —
Cooling System ECT Sensor test. If test fails,
replace sensor. If sensor passes monitor engine
temp using temp gun while watching temp on
Digital Wrench. If temp varies from gun to read out
suspect sensor.
• If concern is still present after sensor replacement,
monitor temp on Digital Wrench and with temp gun.
If read out still varies suspect ECU not receiving
correct signal input.
10. Inspect ECU calibration level.
• If any ECU calibrations are available, update at this
time. The concern may be caused by a corrupted
calibration.
11. Engine Damage
• The overheating concern may be caused by an
engine concern.
• Refer to the necessary section in the Service
Manual for further engine testing.
DIAGNOSTIC
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