COOLING SYSTEM

EAS00454

COOL

RADIATOR
1 2 3 4 5 6 7 8

COOLING SYSTEM
9 0

Radiator cap Bracket Water pump inlet hose Radiator outlet hose Radiator inlet hose Bracket Thermostat housing cover Thermostat

Radiator assembly Fan motor assembly

10 Nm (1.0 mkg, 7.2 ftlb )

9 3

6 5

2 7 8

10 Nm (1.0 mkg, 7.2 ftlb )

10 Nm (1.0 mkg, 7.2 ftlb )

5-1

COOLING SYSTEM
EAS00468

COOL

WATER PUMP
1 2 3 4 5 6 7 8

O-ring O-ring Water pump cover Gasket Plate Impeller Plate Housing cover gasket

9 0 q

Bearing Water pump seal Water pump housing

10 Nm (1.0 mkg, 7.2 ftlb )

5 7 8

LS

q 0 1
LS

2
LS

4 3

10 Nm (1.0 mkg, 7.2 ftlb )

5-2

COOLING SYSTEM

COOL

REMOVING THE RADIATOR

w A hot radiator is under pressure. Therefore,do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove.
1. Remove: 9side cowlings (left and right) 9front cowling 9center panels 9seat assembly with battery box 9inner panel Refer to REMOVING THE FRONT COWLINGS in chapter 3. 2. Drain: 9cooling water Refer to CHANGING THE COOLANT in chapter 3.
1

3. Disconnect: 9radiator inlet hose 9radiator outlet hose 9radiator outlet pipe 9fan motor coupler 1

4. Remove: 9radiator assembly 1 9water pump assembly 2 9O-rings

1 2

5-3

COOLING SYSTEM
5. Remove: 9bracket 9thermostat cover 1 9thermostat 2

COOL

6. Remove: 9fan motor

EAS00455

CHECKING THE RADIATOR

NOTE:

1. Check: 9radiator fins Obstruction Clean. Apply compressed air to the rear of the radiator. Damage Repair or replace.

Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: 9radiator hoses 9radiator pipes Cracks/damage Replace.

5-4

COOLING SYSTEM

COOL

3. Measure: 9radiator cap opening pressure Below the specified pressure Replace the radiator cap.

Radiator cap opening pressure 93.2 122.6 kPa (0.93 1.23 kg/cm2, 13.5 17.8 psi)
MMMMMMMMMMMMMMMMMMMMMMMM a. Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3.

b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
LLLLLLLLLLLLLLLLLLLLLLLL

Radiator cap tester 1 90890-01325 Radiator cap tester adapter 2 90890-01352

4. Check: 9radiator fan motor Damage Replace. Malfunction Check and repair. Refer to COOLING SYSTEM in chapter 8.

5-5

COOLING SYSTEM
EAS00462

COOL

CHECKING THE THERMOSTAT

1. Check: 9thermostat 1 Does not open at 80.5 83.5C (176.9 182.3F) Replace.

MMMMMMMMMMMMMMMMMMMMMMMM

a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermostat and thermometers indicated temperature.
LLLLLLLLLLLLLLLLLLLLLLLL
1 2 3 4

Thermometer Water Thermostat Container Fully closed Fully open

NOTE:

If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or overcooling.

2. Check: 9thermostat housing cover 9thermostat housing Cracks/damage Replace.

EAS00470

DISASSEMBLING THE WATER PUMP

1. Remove: 9water pump cover 9gasket 9O-ring

5-6

COOLING SYSTEM
NOTE:
2. Remove: 9plate

COOL

Slide the plate as shown, and then remove the plate from the water pump housing.

4 1 3

NOTE:

3. Remove: 9impeller 1 9bearing 2

Remove the bearing from the outside of the water pump housing.
3

Water pump housing

NOTE:

4. Remove: 9water pump seal 4

Remove the water pump seal from the inside of the water pump housing.

EAS00473

CHECKING THE WATER PUMP

1. Check: 9water pump housing cover 9water pump housing 9impeller 9rubber damper 9rubber damper holder 9water pump seal 9oil seal Cracks/damage/wear Replace.

2. Check: 9bearing Rough movement Replace.

5-7

COOLING SYSTEM
EAS00475

COOL

ASSEMBLING THE WATER PUMP

NOTE:
1. Install: 9water pump seal 1 Install the water pump seal with the special tools.

Mechanical seal installer 90890-04145 2 Middle driven shaft bearing driver 90890-04058 3

Push down.

2. Lubricate: 9water pump seal 1

Recommended lubricant Lithium soap base grease

3. Install: 9impeller 9plate

NOTE:
9Align

10 Nm (1.0 mkg, 7.2 ftlb)

the slit in the impeller shaft with the slot of the plate. 9After installation, check that the impeller shaft rotates smoothly.
FWD
EAS00467

INSTALLING THE THERMOSTAT

NOTE:
1 2

1. Install: 9thermostat 1 9thermostat cover 2 9bracket 10 Nm (1.0 mkg, 7.2 ftlb)

Face the hole toward to the forward to install.

5-8

COOLING SYSTEM
EAS00478

COOL

LS

INSTALLING THE WATER PUMP

1

1. Install: 9O-rings 9water pump housing 1

10 Nm (1.0 mkg, 7.2 ftlb)

w Always use a new O-ring.

a
LS

NOTE:
9Align

the projection a on the impeller shaft with the slit b on the camshaft. 9Lubricate the O-ring with a thin coat of lithiumsoap-based grease. 2. Install: 9water pump housing cover 2
9water pump inlet hose 9water pump outlet hose

10 Nm (1.0 mkg, 7.2 ftlb)

EAS00456

INSTALLING THE RADIATOR

1. Install: 9radiator assembly

10 Nm (1.0 mkg, 7.2 ftlb)

2. Connect: 9fan motor coupler 9radiator outlet pipe 9radiator outlet hose 9radiator inlet hose 3. Fill: 9cooling system (with the specified amount of the recommended coolant) Refer to CHANGING THE COOLANT in chapter 3.

5-9

COOLING SYSTEM

COOL

4. Check: 9cooling system Leaks Repair or replace any faulty part.

MMMMMMMMMMMMMMMMMMMMMMMM

a. Attach the radiator cap tester 1 to the radiator.

Radiator cap tester 90890-01325 Radiator cap tester adapter 90890-01352

b. Apply 100 kPa (1.0 kg/cm2 , 14.22 psi) of pressure. c. Measure the indicated pressure with the gauge.
LLLLLLLLLLLLLLLLLLLLLLLL

5. Measure: 9radiator cap opening pressure Below the specified pressure Replace the radiator cap. Refer to CHECKING THE RADIATOR. 6. Install: 9inner panel 9seat assembly with battery box 9center panels 9front cowling 9side cowlings (left and right) Refer to REMOVING THE FRONT COWLINGS in chapter 3.

5-10