Polaris SPORTSMAN 400 2003, Service Manual, Page: 37 / 274

MAINTENANCE
2.18
COOLING SYSTEM
PRESSURE TEST
Refer to Page 3.5 for pressure test procedure.
COOLANT LEVEL
INSPECTION
The recovery bottle, located on the left side of the
machine, must be maintained between the minimum
andmaximum levels indicatedontherecoverybottle.
Recovery
Bottle
Accessible
Under Side
Panel
With the engine at operating temperature, the coolant
level should be between the upper and lower marks
on the coolant reservoir. If not:
1. Remove reservoir cap. Inner splash cap vent
hole must be clear and open.
2. Fill reservoir to upper mark with Polaris Premium
60/40 Anti Freeze / Coolant or 50/50 or 60/40
mixture of antifreeze and distilled water as
required for freeze protection in your area.
3. Reinstall 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.
RADIATOR COOLANT LEVEL
INSPECTION
NOTE: This procedure is only required if the cooling
system has been drained for maintenance and/or
repair. However, if the recovery bottle has run dry, or
if overheating is evident, the level in the radiator
should be inspected and coolant added if necessary.
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.
NOTE: Use of a non-standard pressure cap will not
allow the recovery system to function properly.
Rack
Front
Cover
To access the radiator pressure cap:
Remove the four screws securing front rack. Turn
handle bars full left or right to provide more clearance.
Remove front cover by placing your fingers under the
front of the cover and pulling upward.
AIR FILTER/PRE-FILTER
SERVICE
It is recommended that the air filter and pre filter be
replaced annually. When riding in extremely dusty
conditions, replacement is required more often.
The pre filter should be cleaned before each ride using
the following procedure:
1. Lift up on the rear of the seat.
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