4-6
Liquid Cooling System
To check the cooling system, see Section 2.
DRAINING COOLANT
The cooling system does not have a drain; therefore,
coolant must be removed using the following procedure.
1. Using suitable in-line clamps, close off the lower
radiator hose and the coolant bypass hose next to
the water pump.
DE510A
2. Place a suitable drain pan with a capacity of at
least 4 l (4.2 U.S. qt) under the left front of the
engine; then loosen the hose clamp on the coolant
bypass hose.
3. Remove the hose and allow coolant to drain into
the drain pan. A funnel or short hose can be used
to direct coolant into the drain pan.
4. Install the coolant bypass hose and tighten the
clamp securely; then remove the in-line clamps.
FILLING COOLANT
1. Elevate the rear of the ATV approximately 30 cm (12
in.) and secure in place using appropriate blocks.
2. Remove the cap from the filler neck and slowly
pour the recommended amount of coolant into the
system.
3. Move the ATV outside or to a well-ventilated area
and start the engine allowing it to run for several
minutes; then remove the filler cap and check the
coolant level. Add coolant as required until cool-
ant is visible within one inch of the top of the filler
neck.
4. Install the filler cap on the filler neck and tighten
until the cap contacts the stop.
Radiator
REMOVING
1. Drain the coolant at the engine.
2. Remove the front rack (see Section 8).
3. Remove the front bumper and front fender panel
(see Section 8).
4. Remove the upper and lower coolant hoses.
5. Remove the cap screws and nuts securing the radi-
ator to the frame.
6. Disconnect the fan wiring from the main wiring
harness; then remove the radiator/fan assembly
and account for the grommets and collars.
7. Remove the fan/fan shroud assembly from the
radiator.
CC863
CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.
1. Flush the radiator with water to remove any con-
taminants.
2. Inspect the radiator for leaks and damage.
3. Inspect all hoses for cracks and deterioration.
4. Inspect all fasteners and grommets for damage or
wear.
CAUTION
Failure to elevate the rear of the ATV may result in air
being trapped in the cooling system causing severe
engine damage due to overheating.
! WARNING
Do not over-tighten coolant filler cap or excess pres-
sure will build up in the cooling system causing
cooling system damage and possible bodily harm.
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