BRP OEM Thermostat 420222494 Instruction Manual

1. Product Overview

This manual provides essential information for the installation, operation, and maintenance of your BRP OEM Thermostat, part number 420222494. This component is crucial for regulating your engine's operating temperature, ensuring optimal performance and longevity.

Part Number: 420222494

Replaces Part Numbers: 420222493, 711222493

2. Compatibility

This thermostat is compatible with various BRP Can-Am models manufactured between 2006 and 2019. Please verify your vehicle's specific model and year against the list below:

• Outlander 400: 2006-2010, 2011-2012 EFI, 2006-2008 XT HO/Max 400/Max XT HO, 2012 XT EFI, 2011-2012 Max 400 EFI
• Outlander 500: 2007-2010 HO EFI/Max, 2007-2009 XT HO EFI/Max, 2011-2012 EFI/Max
• Outlander 650: 2007-2010 HO EFI, 2007-2009 XT HO EFI, 2012 XT EFI/Max XTP, 2007-2010 Max HO EFI, 2007-2009 Max XT HO EFI, 2011 EFI/Max
• Outlander 800: 2006-2007 EFI, 2011-2012 800R EFI/XMR/500 EFI/500 Max, 2009-2010 Max 800R HO EFI/LTD, 2011-2012 Max 800R LTD EFI
• Renegade 500: 2010-2012 EFI
• Renegade 800: 2007-2008 HO EFI, 2009-2012 800R EFI, 2010-2011 800R XXC EFI
• Commander 800: 2013 800R DPS XT, 2014-2015 800 DPS XT, 2012 800R EFI

3. What's in the Box

Your package should contain the following item:

• One (1) BRP OEM Thermostat (Part Number: 420222494)

Image 1: BRP OEM Thermostat 420222494. This image shows the thermostat, a brass-colored component with a black rubber gasket around its top edge and a spring mechanism at the bottom.

4. Installation (Setup)

Disclaimer: Installation of automotive parts can be complex and may require specialized tools and knowledge. If you are not confident in your ability to perform this installation, it is recommended to seek assistance from a qualified mechanic or service professional. Always refer to your vehicle's specific service manual for detailed, model-specific instructions.

1. Safety First: Ensure the engine is completely cool before beginning any work. Disconnect the negative terminal of the battery to prevent accidental electrical shorts.
2. Drain Coolant: Place a drain pan under the radiator and open the drain cock to drain the engine coolant.
3. Locate Thermostat Housing: The thermostat is typically located in a housing on the engine block or cylinder head, where the upper radiator hose connects.
4. Remove Hoses and Housing: Loosen the clamp and remove the upper radiator hose from the thermostat housing. Carefully unbolt and remove the thermostat housing.
5. Remove Old Thermostat: Note the orientation of the old thermostat before removing it. Clean the mating surfaces of the housing and engine block thoroughly, removing any old gasket material.
6. Install New Thermostat: Install the new BRP OEM Thermostat (420222494) in the correct orientation. Ensure the new gasket (if supplied separately or integrated) is properly seated.
7. Reassemble: Reattach the thermostat housing and tighten bolts to the manufacturer's specified torque. Reconnect the upper radiator hose and tighten its clamp.
8. Refill Coolant: Close the radiator drain cock. Refill the cooling system with the appropriate type and amount of coolant as specified by your vehicle manufacturer.
9. Bleed Air: Start the engine and allow it to reach operating temperature. Monitor the coolant level and add more as needed. Bleed any air from the cooling system according to your vehicle's service manual. Check for leaks.

5. Operating Principles

The thermostat is a temperature-sensitive valve that controls the flow of coolant between the engine and the radiator. When the engine is cold, the thermostat remains closed, allowing the engine to warm up quickly to its optimal operating temperature. Once the engine reaches a predetermined temperature, the thermostat opens, allowing coolant to flow to the radiator for cooling. This process ensures efficient engine operation, fuel economy, and reduced emissions.

6. Maintenance

Proper maintenance of your cooling system, including the thermostat, is vital for vehicle health:

• Coolant Checks: Regularly check your coolant level and condition. Replace coolant according to your vehicle manufacturer's recommendations.
• Hose Inspection: Inspect radiator and heater hoses for cracks, leaks, or swelling. Replace damaged hoses promptly.
• System Flush: Periodically flush your cooling system to remove sediment and contaminants that can impede thermostat function or radiator efficiency.
• Temperature Monitoring: Pay attention to your vehicle's temperature gauge. Consistent overheating or underheating can indicate a thermostat issue.

7. Troubleshooting

If you experience issues with your vehicle's cooling system, consider the following common thermostat-related problems:

• Engine Overheating: If the engine consistently overheats, the thermostat may be stuck in the closed position, preventing coolant from reaching the radiator.
• Engine Running Cold: If the engine takes a long time to warm up or runs consistently below its optimal temperature, the thermostat may be stuck open, allowing too much coolant flow.
• Erratic Temperature Gauge: A fluctuating temperature gauge can sometimes indicate a thermostat that is opening and closing inconsistently.

If you suspect a faulty thermostat, it is recommended to have it inspected and replaced by a qualified professional.

8. Specifications

9. Warranty Information

Specific warranty details for this BRP OEM part are typically provided at the point of purchase or can be found on the official BRP website. Please retain your proof of purchase for any warranty claims. Generally, OEM parts carry a limited warranty against manufacturing defects.

10. Support

For further assistance, technical support, or inquiries regarding this product, please contact your authorized BRP dealer or visit the official BRP customer support website. When contacting support, please have your vehicle's VIN and the thermostat's part number (420222494) available.