RADIATOR

Removing the radiator

Order

Job/Parts to remove

Q’ty

Remarks

 

Coolant

 

Drain.

Refer to CHANGING THE COOLANT.

 

Seat/Side cover (left/right)/Shroud (left/right)

 

Refer to GENERAL CHASSIS.

 

Fuel tank

 

Refer to FUEL TANK.

 

Air filter case

 

Refer to THROTTLE BODY.

1

Radiator guard

2

 

2

Radiator hose clamp

8

Loosen.

3

Radiator fan

1

 

4

Radiator (right)

1

 

5

Radiator hose 2

1

 

6

Radiator hose 4

1

 

7

Radiator hose 3

1

 

Removing the radiator

Order

Job/Parts to remove

Q’ty

Remarks

8

Radiator pipe 2

1

 

9

Radiator breather hose

1

 

10

Radiator (left)

1

 

11

Radiator hose 1

1

 

12

Radiator pipe 1

1

 

13

Coolant temperature sensor

1

 

CHECKING THE RADIATOR

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.Check:

  • Radiator fin “1”

    Obstructions → Clean.

    Apply compressed air to the rear of the radiator.

    Damage → Repair or replace.

Correct any flattened fins with a thin, flat-head screwdriver.

2.Check:

  • Radiator hose

  • Radiator pipe

    Crack/damage → Replace.

3.Check:

  • Radiator cap valve opening pressure

a.Install the radiator cap tester adapter “2” and the radiator cap tester “3” to the radiator cap “1”, and activate the tester to check whether it can stay for 5 to 10 seconds within standard pressure values.

Before attaching the cap to the tester, apply water to its sealing surface.

  • Radiator cap valve opening pressure

    107.9–137.3 kPa (1.08–1.37 kgf/cm², 15.6–19.9 psi)

No stay → Replace.

  • Radiator cap tester

    90890-01325

  • Mityvac cooling system tester kit

    YU-24460-A

  • Radiator cap tester adapter

    90890-01352

  • Pressure tester adapter

    YU-33984

INSTALLING THE RADIATOR

1.Fill:

  • Cooling system

    (with the specified amount of the recommended coolant)

    Refer to CHANGING THE COOLANT.

2.Check:

  • Cooling system

    Leaks → Repair or replace any faulty part.

3.Install:

  • Radiator cap tester “1”

  • Radiator cap tester adapter “2”

    • Radiator cap tester

      90890-01325

    • Mityvac cooling system tester kit

      YU-24460-A

    • Radiator cap tester adapter

      90890-01352

    • Pressure tester adapter

      YU-33984

4.Activate the tester to apply the test pressure.

  • Test pressure value

    137.3 kPa (1.37 kgf/cm², 19.9 psi)

  • Do not apply such a high pressure as exceeds the test pressure.

  • Make sure that a checkup after the cylinder head gasket is replaced is made after 3 minutes of warm-up.

  • Make sure that coolant is filled up to the upper level beforehand.

5.Check:

  • Pressure value

    No stay for 5 to 10 seconds at the test pressure value → Correct.

  • Radiator

  • Radiator hose connection

    Coolant leaks → Correct or replace.

  • Radiator hose

    Bulges → Replace.

    When the radiator cap tester is removed, coolant will spout; therefore, cover it with a cloth beforehand.