Finished putting an '08 thermostat in my son's 2005 1000 Summit that he bought. Not to tough of a project. The most frustration was trying to get the conversion from the 3/4" nipple on the thermostat to mate up to the 1" outlet of the inline T that we installed. We also ended up using a brass 90° elbow to keep from bending the hose to tight and collapsing it. We need to find a preformed hose that goes from 1" to 3/4" and does a 90° bend that is about 8" long. This would make the project goe extremely well.
When he rode it for the first time yesterday and followed him in the 2-3' of powder, I knew right where he went by the black streak that he left. We're hoping that this will eliminate that and will let it run smoother and improve the longevity of the motor.
One concern I have with the project is making sure there isn't an air bubble in the system,when we're done. We filled the coolant res. to the top and raised the front of the sled to where the thermostat was higher than the rear cooler. We then ran the motor at about 3000rpm until we got the tunnel exchanger warm and it used about 1/2 of the coolant res. We then lowered the front and raised the rear and did the same thing. It lowered the coolant res. about an inch. If someone has a more efficient way to rid the system of air bubbles, please post it. We probably drained about a quart when we first cut the hoses and I feel that is what we got back into the system.
Good luck with it!
