All -

I finally replaced my busted beyond
repair radiator (Thanks Dad!) today
in 25 degree cold weather outside
(no garage).

This was my first time doing Quad
repair as my other hands on exp.
has previously been with assembly (bumpers,
winch install). Not too bad just had
to remove whole front end to pull out
RAD, my repair guide didn't even
give me any instruction on this. Just
studied the configuration little and decided
to go for it. (Saved a bunch I'm sure if I
would of paid for professional ATV/Motorcycle
repair with mech labor rates these days?)

Had to remove ft. cargo box, unfasten
Rad fan from behind (no biggie, 4 bolts).
Remove 2 top bolts and pull off 3 hoses
separately allowed drain (finagle to loosen
tension clamps) then remove top front end
bolts to pull back front end to allow space for
pulling out (up) the rad. Then moved over
old top rubber bushings, bottom cushion rings then
installed using reverse method. Filled up with Polaris 60
/40 Polaris premix Antifreeze, allowed to run for abit
then drove around in yard then let run a little more,
filled over-flow reservoir little more.

Whhheeeew, what a day, but very happy to have
repaired myself, fun too eventhough COLD, and
my ole Dad redeemed himself being the culprit
to this Rad attack - LOL

 

rtickwad, just to give you heads up. good job on doing the repair yourself and saving money. when you ran the bike after filling the rad. did you run it w/ the cap on? sometimes if you dont get the air out of the system you will start to have overheat issues. something to consider if this happens is to let the bike run w/ the cap on the first notch(instead of tighting all the way) for a little while so the air has a chance to work its way out. this may not happen but just in case you'll know what to expect.

 

Cost me lil over 800 to have my radiator & fan replaced after finding a steel fence post in a swamp. Was like 325 for rad 230 or so for fan, 2 hrs labor @ $80 + couple misc parts, 2.25 a qt for coolant. Thought was just hung up on something so after backing up & trying again got off & found the bent over post that had ran through radiator twice. Rad & fan were pushed back a ways could not budge them when I tried to pull them out so limped it back the 2 miles to house stopping 2 times to let it cool then getting towed the rest of the way.

 

Upnort -

Wow, what a story, sorry to hear
all the troubles and now after you
have indicated the costly repair I
am definately glad I took this one
on my own to fix. (Little help from
my Dad too..:0)

BTW, watch out for those moving
steel fence posts lurking in those
swamps, LOL...Thanks man!

R'

 

Ste -

(My reply didn't take, strange?)

Anyways, yes I did have it capped all
the way. You know I think I may have
experienced the air bubble thing cause
it was at steady level (between Min and
Max as recommended) then I drove it
around in my yard for a few mins and
after parking it discovered it sucked up
the remaining coolant in the reserve,
so I added to the reserve and then
the levels were fine.

A little hard to gauge if you add enough to
the rad, nothing really to indicate its fill level
cause we monitored that the reserve was
over max filling up so we didn't add anymore.
Then it sucked all of it down after riding it,
strange? Was this the symptom of air?

Should I run again with the cap in notch position
as you recommended?

Good tip Stendori!

R'

 

How much was the rad for the 450 S.P. If you don't mind me asking.......Or just tell me nevermind......................Caper......

 

it wouldnt hurt to run it w/ the cap on the first notch.(dont drive it that way. i let my fan cycle a few times on my 800 when i did mine this summer.i actually wrote this tip on another forum because they were having heat issues after filling the rad. and they came back and said it worked good. another thing to consider is that when the machine is hot or cold you will have 2 differnt levels in the resevior. so dont over fill it when its cold it should be in the middle.

 

Ste -

The fluid level in the reserve is in the middle so I think I am okay,
but when I run it next time I will definately do the cap notch thing.

Cap -

I paid $312 for the new Rad w/$7 for shipping but
that also included a gallon of Polaris Premium Antifreeze
to that order. If you need Ridersville Cycle info. let me know.
FYI, you only get the Radiator itself, you have to use the
same bolts, hoses, bushings, cushion rings. No assembly
instructions nor did I find anything in my repair manual.
I guess all the good mech. know this type of repair is a
no Brainer, ehehe. I feel it would of helped to know about
the front end disassembly as I wasn't sure if removing the
two bolts if the front end would spring back on pivot arms
in which it did look like from the sides, but NO it just came
off, LOL. Good thing I had a hold of the front end (Brush
guard) all in all pretty easy task, even easier if you had a
nice garage to work in (Coming one day!)

R'

 

Thanks.....For the reply....Caper........Glad the install went good for you!!!!