Iapsensorinspection

Theintakeairpressuresensorislocatedattherearsideoftheaircleanerbox.(c::::7'4-36)

Iapsensorremoval/installation

•Liftandsupportthefueltank.(c::::7'4-52)

•RemovetheIAPsensormountingscrewG)anddisconnectthecoupler~andvacuumhose@.

•Installationisinthereverseorderofremoval.

TPSENSORINSPECTION

ThethrottlepositionsensorisinstalledontheNo.4throttlebody.

(c::::7'4-38)

TPSENSORREMOVAL/INSTALLATION

•Liftandsupportthefueltank.(c:::::T4-52)

•RemovetheTPsensorsettingscrewsG)anddisconnectthecoupler(2).

•InstalltheTPsensortotheNo.4throttlebody.Refertopage4-

28ForTPsensorsettingprocedure.

CKPSENSORINSPECTION

Thesignalrotorismountedontherightendofthecrankshaft,andthecrankshaftpositionsensor(Pick-upcoil)isinstalledontherightsideofthemiddlecrankcase.(c::::r4-35)

CKPSENSORREMOVAL/INSTALLATION

(C:::73-23and-80)

CMPSENSORINSPECTION

Thesignalrotorisinstalledontheintakecamshaft,andthecam•shaftpositionsensor(Pick-upcoil)isinstalledonthecylinderheadcover.(C::::?"4-34)

CMPSENSORREMOVAL/INSTALLATION

•Liftandsupportthefueltank.(c:::::T4-52)

•Removetheaircleanerbox.(c::::r4-62)

•DisconnectthecouplerCDandremovetheCMPsensor.

Installationisinthereverseorderofremoval.

Iatsensorinspection

Theintakeairtemperaturesensorisinstalledattherightsideoftheaircleanerbox.(c:::::T4-41)

Iatsensorremoval/installation

•Liftandsupportthefueltank.(c:::?4-52)

•DisconnecttheIATsensorcouplerG)andremovetheIATsen•

sorfromtheaircleanerbox.

•Installationisinthereverseorderofremoval.

(!)IATsensor:18N·m(1.8kqf-rn,13.0lb-ft)

ECTSENSORINSPECTION

Theenginecoolanttemperaturesensorisinstalledattherearsideofthecylinderhead.(c::?4-40and5-8)

ECTSENSORREMOVAUINSTALLATION

(c::?5-8and-9)

APSENSORINSPECTION

TheatmosphericpressuresensorislocatedovertheECM.(CT

4-42)

APSENSORREMOVAUINSTALLATION

•Removethefrontseat.(c::?6-6)

•DisconnectthecouplerG).

•RemovetheAPsensor.

•Installationisinthereverseorderofremoval.

TOSENSORINSPECTION

Thetipoversensorislocatedinaheadofthebatteryholder.

TOSENSORREMOVAUINSTALLATION

•Removethefrontseat.(C76-6)

•Liftandsupportthefueltank.(ct4-52)

•DisconnectthecouplerG)andremovetheTOsensorfromthefueltankbracket.

•Installationisinthereverseorderofremoval.

NOTE:

WheninstallingtheTOsensor.bringthe"UPPER"letteronittothetop.

STPSENSORINSPECTION

ThesecondarythrottlepositionsensorisinstalledontheSTV

actuator.(c::?'4-46)

STPSENSORREMOVAUINSTALLATION

•Liftandsupportthefueltank.(c::?4-52)

•RemovetheSTPsensorsettingscrews(}'!anddisconnectthecoupler~·.

•InstalltheSTPsensortotheSTYactuator.Refertopage4-71forSTPsensorsettingprocedure.

COOLINGANDLUBRICATIONSYSTEM5-1

·COOLINGANDLUBRICATIONSYSTEM

CONTENTS~~~~~~~~~~

ENGINECOOLANT..........................................................................		5-	2
COOLINGCIRCUIT		5-	3
COOLINGCIRCUITINSPECTION................................................		5-	3
RADIATORANDWATERHOSES.....................................................		5-	4
RADIATORREMOVAL..................................................................		5-	4
RADIATORCAPINSPECTION.....................................................		5-	4
RADIATORINSPECTIONANDCLEANING.................................		5-	4
RADIATORREMOUNTING...........................................................		5-	5
WATERHOSEINSPECTION		5-	5
COOLINGFAN...........	.	5-	6
REMOVAL		5-	6
INSPECTION		5-	6
INSTALLATION..............................................................................		5-	6
COOLINGFANTHERMO-SWITCH..................................................		5-	6
REMOVAL		5-	6
INSPECTION		5-	7
INSTALLATION..............................................................................		5-	7
COOLINGFANCONTROLRELAY..................................................		5-	7
INSPECTION		5-	7
ENGINECOOLANTTEMPERATURESENSOR..............................		5-	8
REMOVAL		5-	8
INSPECTION		5-	8
INSTALLATION..............................................................................		5-	9
THERMOSTAT...................................................................................		5-	9
REMOVAL		5-	9
INSPECTION.................................................................................		5-10
INSTALLATION..............................................................................		5-10
WATERPUMP...................................................................................		5-11
REMOVALANDDISASSEMBLY..................................................		5-11
INSPECTION.................................................................................		5-14
REASSEMBLYANDINSTALLATION...........................................		5-15
LUBRICATIONSYSTEM...................................................................		5-18
OILPRESSURE.............................................................................		5-18
OILFILTER		5-18
OILPRESSUREREGULATOR.....................................................		5-18
OILSTRAINER..............................................................................		5-18
OILJET..........................................................................................		5-18
OILPUMP......................................................................................		5-18
OILPRESSURESWITCH.............................................................		5-18
ENGINELUBRICATIONSYSTEMCHART...................................		5-19
ENGINELUBRICATIONSYSTEM................................................		5-20

ENGINECOOLANT

Atthetimeofmanufacture,thecoolingsystemisfilledwitha

50:50mixtureofdistilledwaterandethyleneglycolanti-freeze.This50:50mixturewillprovidetheoptimumcorrosionprotectionandexcellentheatprotection,andwillprotectthecoolingsystemfromfreezingattemperaturesabove-31°C(-24°F).

Ifthemotorcycleistobeexposedtotemperaturesbelow-31°C

(-24°F),thismixingratioshouldbeincreasedupto55%or60%

accordingtothefigure.

_IACAUTIONI

^Anti-freezeFreezingpointdensity

50%-30°C(-24°F)

55%-40°C(-44°F)

60%-55°C(-67°F)

("F)c·q

³²⁰_r-,I

*Useahighqualityethyleneglycolbaseanti-freeze,mixedwithdistilledwater.Donotmixanalcoholbaseanti-freezeanddifferentbrandsofanti-freeze.

*Donotputinmorethan60%anti-freezeorlessthan

50%.(RefertoRightfigure.)

*Donotusearadiatoranti-leakadditive.

_{50%Enginecoolantincludingreservetankcapacity}

14^-10

-4^-20

^-_c^-22-30

_·5

^a_-40-40

O>

·~-58_-50

Q)

^J:-76~o

-94-70

1'\

_\

_\I

\_I

^I

^'.._..^..

Anti-freeze1200ml(3.1/2.6US/Imp.pt)

20406080100

Density(%)

_{Fig.1Enginecoolantdensity-freezing}

Water

1200ml(3.1/2.6US/Imp.pt)

pointcurve.

(Of)(OC)

302150

(kgf/cm2)

284140l---+--1--+--+---'t-=--11.5Q)

_'.5

~

^c2660.9(/)

_{~a_}

s

Cl248120l=---+-"=i---'--+-=1---'40.5Q)

~Cl

2301100~

212100L---i==---.----+.--1---1

0102030405060

Density(%)

Fig.2Enginecoolantdensity-boilingpointcurve.

AWARNING

*Youcanbeinjuredbyscaldingfluidorsteamifyouopentheradiatorcapwhentheengineishot.Aftertheenginecools,wrapathickclotharoundcapandcarefullyremovethecapbyturningitaquarterturntoallowpressuretoescapeandthenturnthecapallthewayoff.

*Theenginemustbecoolbeforeservicingthecoolingsystem.

*Coolantisharmful;

•Ifitcomesincontactwithskinoreyes,flushwithwater.

•Ifswallowedaccidentally,inducevomitingandcallphysicianimmediately.

•Keepitawayfromchildren.

_{COOLINGANDLUBRICATIONSYSTEM5.3}

_{COOLINGCIRCUIT}

RESERVETANK

THERMOSTATCYLINDERHEAD

ENGINECOOLANTTEMPERATURESENSOR

_CYLINDER

RADIATOR

COOLINGFANTHERMOSWITCH

WATERPUMP

_OILCOOLER

COOLINGCIRCUITINSPECTION

Beforeremovingtheradiatoranddrainingtheenginecoolant,inspectthecoolingcircuitfortightness.

•Removetheundercowling.(c:::::J?6-3)

•RemovetheradiatorcapJ1andconnectthetesterq)tothefiller.

AWARNING

Donotremovetheradiatorcapwhentheengineishot.

•Giveapressureofabout120kPa{1.2kgf/cm2,17psi)andseeifthesystemholdsthispressurefor10seconds.

•Ifthepressureshouldfallduringthis10-secondinterval,itmeansthatthereisaleakingpointinthesystem.Insuchacase,inspecttheentiresystemandreplacetheleakingcom•ponentorpart.

AWARNING

Whenremovingtheradiatorcaptester,putaragonthefillertopreventspoutingofenginecoolant.

IACAUTIONI

Donotallowthepressuretoexceedtheradiatorcapre•

leasepressure,ortheradiatorcanbedamaged.

RADIATORANDWATERHOSES

RADIATORREMOVAL

•Removetheundercowling.(c:::::r6-3)

•Drainenginecoolant.(c:::::r2-18)

•Removetheradiator.(c:::::;r3-5)

RADIATORCAPINSPECTION

•FitthecapG)totheradiatorcaptester~.

•Builduppressureslowlybyoperatingthetester.Makesurethatthepressurebuild-upstopsat95-125kPa(0.95-12.5kgf/cm2,13.5-17.8psi)andthat,withthetesterheldstandstill,thecapiscapableofholdingthatpressureforatleast1Oseconds.

•Replacethecapifitisfoundnottosatisfyeitherofthesetwo

requirements.

~Radiatorcapvalveopeningpressure

Standard:95-125kPa

(0.95-1.25kgf/cm2,13.5-17.8psi)

RADIATORINSPECTIONANDCLEANING

•Roaddirtortrashstucktothefinsmustberemoved.

•Useofcompressedairisrecommendedforthiscleaning.

•Finsbentdownordentedcanberepairedbystraighteningthemwiththebladeofasmallscrewdriver.

RADIATORREMOUNTING

•Installtheradiator.

•Routetheradiatorhoses.(c::J"'8-19)

•Pourenginecoolant.(c::7"2-18)

•Bleedtheairfromthecoolingcircuit.(c::::T2-19)

•Installtheundercowling.

WATERHOSEINSPECTION

•Removetheundercowling.(c::::T6-3)

•Anywaterhosefoundinacrackedconditionorflattenedmustbereplaced.

•Anyleakagefromtheconnectingsectionshouldbecorrected

bypropertightening.

COOLINGFAN

REMOVAL

•Removetheundercowling.(c::::7'6-3)

•Drainenginecoolant.(c::::7'2-18)

•Removetheradiator.(c::::7'3-5)

•Removethecoolingfan.