190
CC785A
2. Connect the two coolant hoses to the water pump and
secure with the clamps. Tighten securely.
3. Place the footrest into position on the frame and
loosely secure with four cap screws; then secure the
front and rear fenders to the footrest with the four
torx-head cap screws. Tighten the four torx-head cap
screws securely; then tighten the 8 mm cap screws to
20 ft-lb and the 10 mm cap screws to 40 ft-lb.
4. Fill the engine/transmission with the proper amount
of recommended oil.
5. Fill the cooling system with the proper amount of
recommended coolant.
NOTE: While the cooling system is being filled, air
pockets may develop; therefore, run the engine for
five minutes after the initial fill, shut the engine off,
and then fill the cooling system.
6. Check the entire cooling system for leakage.
WATER PUMP (1000)
NOTE: The water pump is a non-serviceable compo-
nent. It must be replaced as an assembly.
Removing
1. Remove the coolant drain plug; then remove the radia-
tor cap and drain the coolant into a suitable container.
GZ093A
NOTE: Always use a large container and have suffi-
cient floor drying material available when draining
the coolant in case of coolant spillage.
2. Remove the coolant hoses from the water pump; then
remove two cap screws securing the water pump to
the crankcase.
GZ230A
3. Remove the water pump from the engine.
Installing
1. Install a new O-ring onto the water pump and lightly
coat with clean engine oil.
GZ252C
2. Install the water pump assembly onto the engine
aligning the flat drive on the water pump to the slot
in the driveshaft.
GZ252D
CAUTION
After operating the ATV for the initial 5-10 minutes, stop
the engine, allow the engine to cool down, and check
the coolant level. Add coolant as necessary.
CAUTION
Do not force the water pump housing into the crankcase
or severe engine damage may occur.
