Cooling System Pressure Test; Four Stroke - Coolant Air Bleeding Procedure - Polaris 2007 SPORTSMAN X2 800 Service Manual

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 front cover.
2. Remove recovery bottle hose from coolant filler neck.
™
3. Connect a Mity Vac
nipple and pressurize system to 10 psi. The system must
retain 10 psi for five minutes or longer. If pressure loss is
evident within five minutes, check the radiator, hoses,
clamps and water pump seals for leakage.
Radiator Cap Pressure Test
1. Remove radiator cap and test cap using a commercially
available cap tester.
2. The radiator cap relief pressure is 13 psi. Replace cap if it
does not meet this specification.
Fan Assembly
Lower Engine Hose
(PN 2870975) to the filler neck
Upper Engine Hose
Surge Tank
Hose
Radiator
Four Stroke - Coolant Air Bleeding
Procedure
Squeeze Hose
Here to Help
Purge Air From
System
Polaris Premium
Antifreeze
2871534 - Quart
2871323 - Gallon
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 radiator cap and
top off coolant. Leave the cap off of the radiator. Start and
idle machine for 5-10 minutes until steam is visible in the
radiator cap area.
2. Stop the engine and let cool for a few minutes or until 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 hose after the bend
below the filler neck will aid in purging the system of
air. Pump the hose using your hand several times as
shown in the diagram. 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.
3. Always add coolant to the radiator first, filling to the top of
the neck to replace air that has been purged from the system.
Fill the reservoir only after you have completely filled the
cooling system at the radiator filler neck.
4. Repeat Steps 1 and 2 four or five times or until no more
coolant is pulled into the system.
5. In some instances, Steps 1 and 2 may have to be performed
with the radiator cap on to prevent coolant loss.
6. To test, install the radiator cap and idle machine until fan
comes on. Make sure the fan comes on before the hot light.
ENGINE
Pump Hose By
Hand to Help
Purge System
3.15
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