2004 Ski-Doo Racing Handbook, Page 123Get this manual
SECTION 04ENGINE PREPARATION
COOLING SYSTEM LEAK TEST
Install special radiator cap (PN 529 021 400) included in engine leak tester kit (PN 861 749 100) on coolant tankInstall hose pincher (PN 295 000 076) on overflow hoseUsing pump also included in kit pressurize all system through coolant reservoir to 100 kPa (15 PSI)Check all hoses and cylinderbase for coolant leaksSpray soapwater solution and look for air bubbles295 000 076 529 021 400
DISASSEMBLY AND ASSEMBLY
3,4, Sender and Plug
Apply Loctite 592 (PN 413 702 300) thread sealant on sender and plug to avoid leaks
1, Pressure Cap
Check if the cap pressurizes the systemIf not, install new 90 kPa (13 PSI) cap (do not exceed this pressure)
6,7, Radiator and Radiator Protector
Insert radiator protector into radiator C-rail and crimp C-rail at rear endRefer to FRAME for radiator removal
5, Thermostat
To check thermostat, put in water and heat waterThermostat should start to open when water temperature reaches the following degreeIt will be almost fully open at 50C (122F)ENGINE