space is tight. the thermostat is in the head and can be accessed by removing the "neck" that extends below the head. how i would do it for my 04 800:
1. remove airbox
2. pull off carbs from reed boots
3. loosen clamp on the neck that extends below the head and pull off hose - you will loose some coolant. you may want to drain/pump some coolant from your bottle before doing this.
4. 10 mm socket/wrench - unbolt neck from head
5. once neck is removed, the thermostat will come out.
when reinstalling, use some blue locktite on the neck. good luck.
No need to lower the opening temp.......it is allready the LOWEST in the industry........108*F
I have seen about 3 thermostat problems........s it is a valid idea to remove it.
if you remov it, YOU HAVE TO RESTRICT HE BYPASS HOSE!!!!!!!!!!!
This is the hose that runsfrom the top of the head to the coolant bottle..
I recomend getting a wood or steel DOWLE, that just fits inside that hose, and drill a 1/16" hole in the center of it.......stuff it in the hose, and install a hoseclamp around t, so it doesn't move.
I would HIGHLY recomend installing a temp gauge when doing this, and make sure you never ride the sled hard AT ALL unless the temp is at least 110*F.........you might find that in GOOD snow conditions, that the temp will be way to cold (under 100*) even when riding hard!
This is why I have choseen to do the following.......I drill 4 - 1/16" holes in the stat. I installed an 11/16" cheapo socket in the upper coolant hoe to restrict it slightly. This forcessme water through the heat exchanger, even when the engine is cold.......this PRE HEATS the exchanger, so that when the stat finally opens, you don't have a huge rush of COLD coolant filling your engine......and causing a cold seize!
ski-doo only has one temp. with my delete kit, and a temp gauge, I always run half or just over on cold days and warmer on warm days, tryed the 4 - 3/16 holes in the stat a small decrease in temp, just dropped the stat, plugged the res hose, will see what happens .
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