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Discussion Starter #1
I'm going crazy trying to figure out where I am leaking coolant on my 98 ZRT800, at first I thought that it was the base gasket so I replaced it and it still leaks. I give the symptons and if any body can diagnose this I would really appreciate it.
Symptons= Coolant drops on and around the center carb predomiantly on the rubber spigot that coonacts the carb to the motor, also getting some on rubber airbox connector but it seems to be mainly getting on the center carb and intank and laying around the base of the center cylinder I have looked at the heads and there does not seem to be any apparent coolant trail leaking down the cylinder just on the base I also stuck a piston in this cylinder and thats when I changed the base gasket. I think that it must just leak at high rpm's because you cannot notice it when it is idling or not revving much it's just after you take it for a long rip.
 

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Maybe its leaking out of the reservoir and splashing onto the engine? that would explain why you only find it after a ride. Just a thought...
 

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Hi.  Maybe you should check the waterpump seal.  I had a 800 same year that did the same thing and the pump seal was blown.
 

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This is interesting, because I have the same problem with my 2001 800 ZRT, and so did my buddy with his 2001 Thundercat.
There was antifreeze on the cernter carb. Both machines have less than 400 miles. The dealer said to check all the hose clamps, and I did have one that was kind of loose, and only had a chance to ride it once since then. It seems to be coming from the thermostat housing, and I will ride it this weekend to see if it still leaks.  The dealer told me he had not ever heard of this happening, but there may be a problem here if it is happening to other sleds.
 I did not see any recalls on this.
 

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Well, I had that same problem on a 1996 T-Cat. Turned out to be the coolent manifold gasket that connects to each cyl. head. I could not find the leak until the gasket failed.

   -Auggie-
 

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Discussion Starter #8
I made sure that all of my clamps and bolts were tight that related to the coolant system and although none seemed loose only a slight turn here or there after 70 miles on sat no sign of any coolant leak so I hope I have cured it. Sled ran excellent and the trails are excellent.
 

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My 99 had a early leak at thermostat housing, only leaked when running, kind of sprayed back on center carb and air box (when it was in there)  i believe it was therm. houseing gasket, dealer fixed under warr,
 
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