Radiator cap tester adapter 90890-01352, YU-33984
• Apply the specified pressure for ten sec-onds and make sure that there is no drop in
pressure.
▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲
13. Check:
radiator fan Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
6 - 3
| RADIATOR AND OIL COOLER
| COOL
|
|
| EAS00458
|
|
|
|
| CHECKING THE OIL COOLER
|
|
| 1. Check:
|
|
|
|
| • oil cooler
|
|
|
|
| Cracks/damage → Replace.
|
|
| 2. Check:
|
|
|
|
| • oil cooler inlet hose
|
|
|
| • oil cooler outlet hose
|
|
|
| Cracks/damage/wear → Replace.
|
|
| EAS00459
|
|
|
|
| INSTALLING THE OIL COOLER AND
|
|
| RADIATOR
|
|
|
|
| 1. Clean:
|
|
|
|
| • mating surfaces of the oil cooler and the
|
|
| crankcase
|
|
|
|
| (with a cloth dampened with lacquer thin-
|
|
| ner)
|
|
|
|
| 2. Install:
|
|
|
|
| • O-ring New
|
|
|
|
| • oil cooler 1
|
|
|
|
| • oil cooler bolt 2
|
|
|
b
|
| T.R.
| 63 Nm (6.3 m · kg, 45 ft · lb)
|
| • oil filter cartridge
|
|
|
|
|
|
|
|
| T.R.
| 17 Nm (1.7 m · kg, 12 ft · lb)
|
a
|
| Oil filter wrench
|
|
| 90890-01469
|
|
|
|
|
|
| NOTE:
|
|
|
|
| • Before installing the oil cooler, lubricate the
|
|
| oil cooler bolt with engine oil.
|
|
| • Make sure that the O-ring is positioned prop-
|
|
| erly.
|
|
|
|
| • Align the projection a on the oil cooler with
|
|
| the slot b in the crankcase.
|
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image983.jpg)
3. Fill:
• cooling system
(with the specified amount of the recom-mended coolant)
Refer to “CHANGING THE COOLANT” in chapter 3.
• crankcase
(with the specified amount of the recom-mended engine oil)
Refer to “CHANGING THE ENGINE OIL” in chapter 3.
6 - 4
RADIATOR AND OIL COOLER COOL
| 4. Check:
| |
| • cooling system
| |
Leaks → Repair or replace any faulty part.
| |
| |
| ▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼
| |
| a. Attach the radiator cap tester 1 to the radi-
| |
| ator.
| |
| Radiator cap tester
| |
| 90890-01325, YU-24460-01
| |
| Radiator cap tester adapter
| |
| 90890-01352, YU-33984
| |
| b. Apply 100 kPa (1.0 kg/cm2, 14.22 psi) of
| |
| pressure.
| |
| c. Measure the indicated pressure with the
| |
| gauge.
| |
| ▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲
| |
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image984.jpg)
5. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6 - 5
THERMOSTAT COOL
THERMOSTAT
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image985.jpg)
R.
| 18 Nm (1.8 m
| •
| kg, 13 ft
| •
| Ib)
|
T.
|
|
|
|
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
New 4
Order
| Job/Part
| Q’ty
| Remarks
|
|
|
|
|
| Removing the thermostat
|
| Remove the parts in the order listed.
|
| Center cover/side cover
|
| Refer to “COVER AND PANEL” in chap-
|
|
|
| ter 3.
|
| Coolant
|
| Drain.
|
|
|
| Refer to “CHANGING THE COOLANT” in
|
|
|
| chapter 3.
|
| Thermostat outlet hose
|
| Disconnect.
|
| Coolant temperature sensor coupler
|
| Disconnect.
|
| Coolant temperature sensor
|
|
|
| Copper washer
|
|
|
| Thermostat cover
|
|
|
| Thermostat
|
| Refer to “INSTALLING THE THERMO-
|
|
|
| STAT”.
|
|
|
| For installation, reverse the removal pro-
|
|
|
| cedure.
|
|
|
|
|
6 - 6
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image989.jpg)
a
THERMOSTAT COOL
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image990.jpg)
EAS00462
CHECKING THE THERMOSTAT
13. Check:
thermostat
Does not open at 69 ~ 73 °C (156.2 ~ 163.4 °F) → Replace.
▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼
14. Suspend the thermostat in a container filled with water.
15. Slowly heat the water.
16. Place a thermometer in the water.
17. While stirring the water, observe the ther-mostat and thermometer’s indicated tem-
perature.
▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲
16. Thermostat
17. Thermometer
18. Water
19. Container И Fully closed Й Fully opens
NOTE:
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image237.jpg)
If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause seri-ous overheating or overcooling.
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image979.jpg)
13. Check:
thermostat cover
thermostat housing (cylinder head) Cracks/damage → Replace.
EAS00467
INSTALLING THE THERMOSTAT
16. Install:
thermostat
thermostat cover
T.R.
| 10 Nm (1.0 m · kg, 7.2 ft · lb)
|
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image572.jpg)
NOTE:
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image237.jpg)
Install the thermostat with its breather hole a facing forward.
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image979.jpg)
2. Install:
• copper washer New
• coolant temperature sensor
T.R.
| 18 Nm (1.8 m · kg, 13 ft · lb)
|
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image235.jpg)
6 - 7
THERMOSTAT COOL
11. Fill:
• cooling system
(with the specified amount of the recom-mended coolant)
Refer to “CHANGING THE COOLANT” in chapter 3.
12. Check:
• cooling system
Leaks → Repair or replace any faulty part.
13. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.
6 - 8
WATER PUMP COOL
WATER PUMP
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image991.jpg)
Order
| Job/Part
| Q’ty
| Remarks
|
|
|
|
|
| Removing the water pump
|
| Remove the parts in the order listed.
|
| Left upper side cover moulding/left
|
| Refer to “COVER AND PANEL” in chap-
|
| footrest board
|
| ter 3.
|
| Coolant
|
| Drain.
|
|
|
| Refer to “CHANGING THE COOLANT” in
|
|
|
| chapter 3.
|
| V-belt case air filter element clamp joint
|
| Loosen.
|
| V-belt case air filter element (left)
|
|
|
| Generator cover protector cover
|
|
|
| Generator cover protector
|
|
|
| Oil cooler inlet hose
|
| Disconnect.
|
| Coolant hose
|
| Disconnect.
|
| Radiator outlet hose
|
| Disconnect.
|
| Water pump inlet pipe
|
|
|
| Water pump outlet pipe
|
|
|
|
|
|
|
6 - 9
WATER PUMP COOL
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image991.jpg)
Order
| Job/Part
| Q’ty
| Remarks
|
|
|
|
|
| Water pump assembly
|
| Refer to “INSTALLING THE WATER
|
|
|
| PUMP”.
|
|
|
| For installation, reverse the removal pro-
|
|
|
| cedure.
|
|
|
|
|
6 - 10
WATER PUMP COOL
![](https://konspekta.net/megalektsiiru/baza9/6992425436377.files/image992.jpg)
Order
| Job/Part
| Q’ty
|
|
|
| Remarks
|
|
|
|
|
|
|
| Disassembling the water pump
|
|
| Remove the parts in the order listed.
|
|
|
|
| NOTE:
|
|
|
|
|
|
| It is not necessary to remove the impeller
|
|
|
|
| shaft, unless the coolant level is extremely
|
|
|
|
| low or coolant contains engine oil.
|
| Water pump housing cover
|
|
|
|
|
|
|
|
|
|
|
|
| O-ring
|
|
|
|
|
|
|
| Circlip
|
|
|
|
|
|
|
| Impeller shaft
|
|
|
| Refer to “DISASSEMBLING THE
|
|
|
| Water pump seal
|
|
|
|
|
| WATER PUMP” and “ASSEMBLING
|
| Bearing
|
|
|
|
|
|
|
| THE WATER PUMP”.
|
| Oil seal
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| Water pump housing
|
|
|
|
|
|
|
|
|
|
| For assembly, reverse the disassembly
|
|
|
|
| procedure.
|
|
|
|
|
|
|
|
|
6 - 11
WATER PUMP COOL
EAS00471
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