How to Install SuperATV Radiator on the Polaris RZR 1000

We recently installed the Super ATV aluminum radiator as a DIY in our Polaris RZR XP4 1000. A couple weeks back, the stock radiator started leaking heavily on the trail from a pin hole above the fan.  After relieving itself on the trail and leaving us high and dry, we were able to get the RZR back to a property.  With no chance of repair, we decided to upgrade to a beefier aluminum radiator kit to improve cooling.  Not at the shop and in a garage type situation that most customers would be in, we did the swap with basic tools.

Removing the stock one is easy requiring you to unbolt the support braces. You need a multi-tool torx wrench or socket as well as a 10mm. Using needle nose pliers, you can move the radiator hose clamps down the hose to slip them off the fittings.  With the remainder of the coolant drained, simply unclip the the fan wire plug and you are ready to remove it.  To get the radiator out, you can rotate it clockwise and up.  Once out, unbolt the factory SPAL fan with the 10mm.

The SuperATV aluminum radiator is really well designed.  It includes a new radiator cap, features clean welds, and of course, is thicker than factory.  The stock fan fits on well but one hole was slightly off so had to keep all loose and push sideways for the one bolt to thread in place.  Just like getting the stock one out, to install this, you need to rotate the new assembled one in. Once the bottom rubber grommets are in, you can attach the hoses and put the clamps back.  The only area that requires a little extra elbow grease is the top support braces.  Since the radiator is thicker, the top rubber grommets will not fit in the same place.  If SuperATV would supply a new bracket, this would be a slam dunk.  Doing this as a home project, we did not have the tools on site to drill a new hole.  Rather wait another weekend, we decided in the interim to tighten down the bracket on top of the grommets to hold it in place and then use zip ties.  Have no fear, a proper fix will be done later!

This is a definite upgrade from the factory unit and not bad for $199.  Typical driving temperatures stayed around 184F.  Overall this is a great RZR upgrade!

Get your SuperATV Polaris Radiator Kit Here.