Adding radiator and thermostat to Polaris Ultra Touring. - Snowmobile Forum: Your #1 Snowmobile Forum
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post #1 of 12 (permalink) Old 05-26-2019, 03:48 PM Thread Starter
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Adding radiator and thermostat to Polaris Ultra Touring.

Hey guys, I have been looking into possibly adding a radiator to my snowmobile. I have been looking around to see any info on snowmobiles with radiators and some of the newer models come with them straight out of the factory. some other threads I was viewing people say they don't like them because they add weight and get clogged easily in powder which I understand.. But here in South central MN I think having one would be very useful. Lately the early winters have been barely putting out snow... just enough for fan cooled sleds to get around but I would like to be able to have the luxury of riding and ice fishing with the ultra in low snow conditions. I don't believe this would be a very hard project to tackle but I just want to get some things straight.

1: Snowmobiles can be over cooled.. So adding the radiator not only would add extra cooling ability, but more coolant capacity which means longer warm up times and high risk of overcooling so the engine would cold seize. Now in order to solve this issue a thermostat would be needed, which I found out my sled does not have. Other 1997 Polaris models had them (XCR 600) so I am wondering if I could swap one of them into the cooling system. OR if aftermarket ones are made, I have heard some people talking about "in line" thermostats so I will have to look into that.

2: I would have to figure out where to mount the radiator.. I am thinking right above where the exhaust pipe connects to the engine and use those threads and nuts to mount it. I would have to also figure out what size radiator I would need to fit under there but also not be too small for lack of cooling.. I heard some people use ATV rads in sleds for dune riding but I see a cheap Polaris IQ rad on eBay I could probably get to work.

Anyone got any advice on the matter? thanks - jim.
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post #2 of 12 (permalink) Old 05-26-2019, 10:51 PM
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Can Not over cool, there is a thermostat.
Just add a cars heater core any where you have air flow!
Im a plumber and do alot of Hydronic heating!
All you need to do any where in the system add a in line cooler/ inter cooler!
Basic heat sink, heck Polaris used to run a coolant threw the brake caliper!
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post #3 of 12 (permalink) Old 06-06-2019, 11:49 PM Thread Starter
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Thanks for the response, but I am a little confused when you say there is a thermostat.. Do you mean the pressure cap? and does that work the same as a thermostat? I just don't see any thermostat on the oem parts diagram. sorry for my ignorance as I am not a genius when it comes to these things. A heater core works the same as a radiator correct? just a smaller version from the looks of it. I know my snowmobile has that liquid cooled braking system as well as you mentioned above. Do you know much about ice scratchers? would those help keep it from overheating? I have heard mixed opinions on them.
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post #4 of 12 (permalink) Old 06-07-2019, 07:00 AM
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There should be a therm under the outlet on top.
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post #5 of 12 (permalink) Old 06-07-2019, 09:55 AM
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Possibly no thermostat, mine doesn't have it nor do the other 2 Polaris sleds we have. A 1992, 1997 and 1998 and they all have just a pressure cap system on them with no thermostat to be found. For some odd reason Polaris sleds don't come with them I've never understood it either but they system works.
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post #6 of 12 (permalink) Old 06-07-2019, 10:00 AM
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Also I'd like to know where you heard or saw a thermostat in the 1997 XC 600 as the diagrams do not show one as you have also said. Just a pressure cap setup like the rest of them. Each use a different LB rated pressure cap that is for certain as mine is a 19-21lb cap which seems crazy for that small system but a XC 600 has a 10lb cap iirc. Polaris made some weird decisions during those years that even as someone who sold the bloody things at a couple places I did parts at and some of the stuff drove all of us crazy then. Even the one guy I know who still runs a different Polaris dealership in Illinois to this day he an I still talk now and then about the stuff we come across on those older sleds.

I would do this if you are really concerned about overheating then I would consider a threw hose thermostat as a back up as you mentioned. As you have I have seen it done on those older sleds and it "seems" to work but imho idk what kind of riding you do but that engine is definitely not one you want to overheat. I had the overheat lamp on my 1997 Ultra SP turn on and I freaked out. So glad it was just a bad clamp and the 13LB iirc pressure cap was bad and yes those can go bad. I replace mine every 5 years regardless because at 5 bucks or cheaper from Fleet-Farm it is worth it to me.

Also that sled "should" have 3 radiators already, one on each side just under your feet and the third a far rear 3rd radiator. Even the Ultra SP shows it as being a radiator vs the Ultra Touring saying it is a radiator "weld" or some garbage. If it has fins on it then it is a stock polaris radiator and with those 3 you will be ok. My 500s & 440 have 1 on each side then a small exchanger in front of the bulkhead.

Last edited by Coolhand; 06-07-2019 at 10:15 AM.
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post #7 of 12 (permalink) Old 06-07-2019, 11:41 PM Thread Starter
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It is a XCR 600, not XC 600. Here is the link, (see parts 1-5): https://www.polarispartshouse.com/oe...ean-600-xcr-se . I just ride trails and ditches and lakes. It has blown up before because it apparently had a hole in the coolant reservoir and I wasn't watching the temp gauge, (First liquid cooled sled, and I was a dumb 16 year old.) Expensive mistake but there was plenty of snow so it should have been fine if all was in working order. It does have the 3 heat exchangers you mention but those are cooled with snow and ice. A radiator would use airflow to cool it which would be good for the low snow ice fishing scenarios.
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post #8 of 12 (permalink) Old 06-07-2019, 11:49 PM
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First thing I would do is mount some ice scratchers on the ski spindles. They will scrape ice from the lake or hardpack and toss it up on the heat exchangers under the running boards. I had wire ones on a 1990 Indy 650 and it helped a ton on the hardpack trails



These are different than the ones I had and look more efficient and reliable


https://www.denniskirk.com/ottp/reve....prd/05399.sku

2017 SKS 800, 2007 Dragon RMK 700 155", 2008 RMK 600 155", 95 Prowler 550 2-up, Really OLD AC Cheetah

http://www.avalanche.org/accidents.php
http://www.kbsnowdrifters.org/
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post #9 of 12 (permalink) Old 06-08-2019, 07:44 PM
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That link is about how I remember most Indys being with addition of the brake caliper having coolant too!
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post #10 of 12 (permalink) Old 06-08-2019, 11:25 PM Thread Starter
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Yeah BC_Dan, I was looking at those ski scratchers as well, seem pretty low profile compared to other scratchers plus are reversible which is a plus and seem to have better downwards pressure so it will dig up more ice. I was looking at the Duraflex scratchers but some of the reviews on amazon have stated they are not very good for scratching up ice, not to mention they don't seem like you can put them away when you don't want to use them.. I also heard someone say it will reduce the effectiveness if you bend them out of use for extended periods of time. I will probably just invest in those Ice storm scratchers to float my boat on this cooling deal.
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post #11 of 12 (permalink) Old 06-09-2019, 11:43 AM
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As dan said ice scratchers will throw it up there along with help cool your hyfax at the same time. Been snowmobiling for close to 40 years with 30 of those with liquid cooled from Polaris and everyone has had snow end up on them from the way I ride and where I ride as the trails here in Wisconsin are close to yours for snowfall and I never have a problem. Hell I had a '97 Ultra and the cooling on it wasn't an issue. We don't get a lot of snow here north of Green Bay. Last year was one of the few in years and years were we had a lot of snow but normally our average is around 35-40 inches for the entire season. We have low snow conditions as well.

So I was wrong on it being a XC 600. Also you won't be able to add that to your cylinder head like it is on the XCR unless you go and change a whole lot. As KC has said a external thermostat would be your option.
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post #12 of 12 (permalink) Old 06-09-2019, 02:04 PM
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The ski scratchers are more effective when you have heat exchangers under your feet out of the tunnel. The ones that mount on the rail work ok for heat exchangers in the tunnel. They are coming up with more and more options for ice scratchers, which is a good thing. It's nice to have options

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