Service Manual

2.21
MAINTENANCE
2
COOLING SYSTEM
Cooling System Overview
The engine coolant level is controlled, or maintained, by the
recovery system. The recovery system components are the
recovery bottle, radiator filler neck, radiator pressure cap and
connecting hose.
As coolant operating temperature increases, the expanding
(heated) excess coolant is forced out of the radiator past the
pressure cap and into the recovery bottle. As engine coolant
temperature decreases the contracting (cooled) coolant is drawn
back up from the bottle, past the pressure cap, and into the
radiator.
NOTE: Some coolant level drop on new vehicles is
normal as the system is purging itself of trapped air.
Observe coolant level often during the break-in
period.
Polaris recommends the use of Polaris Premium 60/40 anti-
freeze/coolant or a 50/50 mixture of high quality aluminum
compatible anti-freeze/coolant and distilled water.
NOTE: Polaris Premium 60/40 is already premixed
and ready to use. Do not dilute with water.
Coolant Level Inspection
The pressure cap and recovery bottle are located underneath the
front rack as shown below. Maintain the coolant level between
the “MIN” and “MAX” levels indicated on the recovery bottle.
With the engine at operating temperature, the coolant level
should be between the MAX and MIN marks on the coolant
recovery bottle. If not, perform the following procedure.
1. Position the vehicle on a level surface.
2. View the coolant level in the recovery bottle. The coolant
level can be viewed from inside the front right wheel well.
3. If the coolant level is below the “MIN” line on the bottle,
remove the front rack assembly to access the radiator
pressure cap and recovery bottle cap.
NOTE: If overheating is evident, allow system to
cool completely and check coolant level in the
radiator and inspect for signs of trapped air in
system.
4. Remove the pressure cap. Using a funnel, add coolant to
the top of the radiator filler neck.
5. Reinstall the pressure cap.
NOTE: Use of a non-standard pressure cap will not
allow the recovery system to function properly.
6. Remove recovery bottle cap and add coolant using a funnel.
7. Fill recovery bottle to “MAX” level with Polaris Premium
60/40 Anti-Freeze/Coolant or a 50/50 mixture of anti-
freeze/coolant and distilled water as required for freeze
protection in your area.
8. Reinstall the recovery bottle cap.
CAUTION
Overheating of engine could occur if air is not
fully purged from system.
WARNING
Never remove the pressure cap when the
engine is warm or hot. Escaping steam can
cause severe burns. The engine must be cool
before removing the pressure cap.