COOLING SYSTEM 3-1

Coolant

View

Level Chart Inspection

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Table of Contents

Water Pump Pump Inspection , ..

Radiator and Radiator

Inspection

Fan ..

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..3-2

..3-3

..3-3

..3-3

..3-4

..3-5

..3-5

..3-5

..3-5

..3-6

..3-7

...3-7

...3-7

...3-7

...3-8

...3-8

...3-8

...3-9

.3-10

.3-10

.3-10

.3-10

3-2 COOLING

Exploded View

SYSTEM

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T1 : 2.0 N-m (0.2 kg-m. 17 in-Ib)

T2 : 3.4 N-m (0.35 kg-m. 30 in-Ib)

T3 : 7.8 N-m (0.8 kg-m. 69 in-Ib)

T4 : 8.8 N-m (0.9 kg-m. 78 in-Ib)

T5 : 18 N-m (1.8 kg-m.13 ft-Ib) l : Apply a non-permanent locking agent to the threads.

SS: Apply silicone sealant to the threads.

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COOLING SYSTEM 3-3

Specifications

Items

Coolant:

Type

Color

Mixed ratio

Freezing point

Total amount

Radiator:

Cap relief pressure

Thermostat:

Valve opening temperature

Valve full opening lift

Standard

Permanent type of antifreeze for aluminum engines and radiators

Green

Soft water 50%, coolant 50%

-35°C ( -31°F)

2.3 L (reservoir tank full level)

93 -123 kPa (0.95 -1 .25 kg/cm2, 14 -18 psi)

80.0 -84.0°C (176 -183°F)

Not less than 6 mm @95°C (203°F)

Sealant

Special Tool

Socket Wrench, Hex 8: 57001 -1 268

3-4 COOLING SYSTEM

Coolant Flow Chart

When the engine is cold, the thermostat is closed so that the coolant flow is restricted through the small hole

(air hole) on the thermostat, causing the engine to warm up more quickly.

Coolant

Coolant Level Inspection

NOTE

OCheck the level when the engine is cold (room or ambient temperature).

.Check the coolant level in the reservoir tank with the motorcycle held perpendicularly.

.Check the coolant level from between the fuel tank and the flame at the left side.

* If the coolant level is lower than the lower level line, add coolant to the upper level line.

COOLING SYSTEM 3-5

.Remove the fairings.

.Place a container under the engine.

.Remove the drain plug.

A. Water Pump

.Remove the following.

Radiator Cap

Cylinder Drain Plugs

B. Drain Plug

A. Reservoir Tank

B. Upper Level

Co Lower Level

Do Mounting Bolt

.To remove the reservoir tank, remove the fuel tank.

Coolant Draining

A. Cylinder Drain Plugs

.The coolant will drain from the radiator and engine.

Coolant Filling

.Tighten the drain plugs to the specified torque (see

Exploded View).

.Fill the radiator up to the thermostat housing filler neck with coolant.

3-6 COOLING SYSTEM

Pressure

.Remove

T esting the radiator cap, and install a cooling pressure tester on the radiator filler neck.

system

NOTE

0 Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.

.Build up pressure in the system carefully until the pressure reaches 123 kPa (1.25 kg/cm2, 18 psi).

A. Radiator

B. Filler Neck o Fill the reservoir tank up to the upper level line with coolant.

NOTE o Pour in the coolant slowly so that it can expel the air from the engine and radiator.

.Watch the gauge for at least 6 seconds.

*If the pressure holds steady, the system is all right.

Water and Coolant Mixture Ratio (Recommended)

Soft Water

Coolant

Freezing Point

Total Amount

50%

50%

-35°C ( -31°F)

2.3 L

NOTE

0 Choose a suitable mixture ratio by referring to the coolant manufacturel s directions.

OStart the engine with the radiator cap removed and run it until no more air bubbles can be seen in the coolant.

OTap the radiator hoses to force any air bubbles caught inside.

O Stop the engine and add coolant up to the radiator filler neck.

.Install the radiator cap.

.Fill the reservoir tank up to the upper level line with coolant and install the cap.

CAUTION

Do not add more coolant above the upper level line.

1. Pressure

2. Adapter

Tester

3. Radiator Filler Neck

*If the pressure drops soon, check for leaks.

Water Pump

Removal

.Remove the fairings.

.Drain the coolant by removing the water pump drain plug.

.Remove the following.

Shift Lever

Engine Sprocket Cover

Radiator Hose Clamp on Water Pump

Water Pipe

Water Pump Mounting Bolts(2)

COOLING SYSTEM 3-7

Water Pump Pipe Mounting Bolt

Radiator Hose Clamp Bolt

.Apply a non-permanent locking agent to the engine sprocket cover bolt (one bolt only -see Final Drive chapter).

.Install the water pump cover.

.Fill the coolant (see Coolant Filling).

Water Pump Inspection

.Check the drainage outlet passage at the bottom of the water pump body for coolant leaks.

* If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage.

Replace the water pump unit.

A. Water Pump

B. Mounting Bolts

.Pull the water pump out of the crankcase and the radiator hose.

A. Drainage Outlet Passage

(at the bottom of the pump body)

! nsta!!ation

.Install the water pump with the water pump cover removed.

.Turn the water pump impeller so that the water pump shaft slot fits the oil pump shaft projection.

A. Water Pump Shaft

B. Oil Pump Shaft

.Install the water pipe.

.Tighten the following bolts to the specified torque (see

Exploded View).

Water Pump Mounting Bolts

3-8 COOliNG SYSTEM

Radiator and Radiator Fan

Removal

The radiator fan is connected directly to the battery.

The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE

RADIATOR FAN CONNECTOR IS DISCONNECTED.

TOUCHING THE FAN BEFORE THE CONNECTOR IS

DISCONNECTED

FAN BLADES.

COULD CAUSE INJURY FROM THE

.Remove the following.

Fairings

Fuel Tank (see Fuel System chapter)

Coolant (drain: see Water Pump Removal)

Baffle Plate

Radiator Fan Connector

A. Radiator Hose

Radiator Lower Mounting Bolts

Radiator Side Mounting Bolts

A. Radiator Fan Connector

Radiator Fan Switch Connector

Radiator Hoses

A. Radiator Fan Switch Connector

B. Radiator Hose

A. Lower Mounting Bolts

B. Side Mounting Bolts

.Remove the radiator

Radiator Inspection

.Check the radiator core.

*If there are obstructions to air flow, remove them.

*If the corrugated fins are deformed, carefully straighten them.

* If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.

COOLING SYSTEM 3-9

1. Steam Gun Running Direction

Radiator Cap Inspection

.Check the condition of the top and bottom valve seals of the radiator cap.

* If anyone of them shows visible damage, replace the cap.

1. Pressure Tester 2. Radiator Cap

.Watching the pressure gauge, pump the pressure tester to build up the pressure. The cap must open at the relief pressure (the gauge pointer flicks down). Also the cap must hold any pressure less than the relief pressure for at least 6 seconds.

Radiator Cap Relief Pressure

Standard: 93 ~ 123 kPa

(0.95 -1.25 kg/cm2, 14 -18 psi)

*If the cap cannot hold the specified pressure, or if it holds too much pressure, replace it with a new one.

1 .Bottom Valve Seal

2. Top Valve Seal

3. Valve Spring

.Install the cap on a cooling system pressure tester.

NOTE

0 Wet the cap sealing surfaces with water or coolant to prevent pressure leakage.

3-10 COOLING SYSTEM

Thermostat

Removal

.Remove the fairing and the side cover assembly.

.Drain coolant (cylinder head, cylinder).

.Remove the following.

Carburetor (see Fuel System chapter)

Hose (Thermostat Housing)

Mounting Bolts

Water Temperature Sensor Connector

.Remove the thermostat housir,g on the cylinder.

.Remove the thermostat from the housing.

A. Housing

B. Mounting Bolt

I nsta!lation

.Install the thermostat noting the following.

.Install the thermostat so that the stay faces outside.

.Be sure to install the O-ring on the housing.

.Add coolant (see Coolant Filling).

Inspection

.Remove the thermostat and inspect the thermostat valve at room temperature.

*If the valve is open, replace the valve with a new one.

.To check valve opening temperature, suspend the thermostat in a container of water and raise the temperature of the water.

1 .Thermostat

2. Thermometer

*If the measurement is out of the specified range, replace the thermostat.

Thermostat Valve Opening Temperature

80 -84°C (176 -183°F)