12.6 ServiceManual-RocketIll

Filling

1. Ifremoved,refitthewaterpumpdrainplug.Tightentheplugto10Nm.

2. Reconnect the bottomhoseandtightentheclip.

3. Openthecoolingsystembleedscrew.

1.Bleedscrew

4. Slowlyaddcoolantmixturetothesystem,through thefilleropeningintheradiator,untilcoolantescapesfromthebleedscrew.Closethebleedscrew,tighteningitto10Nm.

5. Ifnecessary,topupthesystemthroughtheradiatorfiller.

6. Refitthepressurecap.

7. Startthemotorcycleandallowtheenginetoidleforashortperiodoftimetoallowanyairtobeexpelledfromthesystem.

B.Stoptheengineandtopupthecoolantlevelasnecessary.

9. Refitthecoolantpressurecapandtightenthesecurityscrew to3Nm.

10. Refitthelefthandradiatorcover,tighteningthefixingsto3Nm.

11. Checkthe expansiontanklevelandtopupifnecessary(seepage12.5).

WaterPump

Removal

1. Removetherider'sseat.

2. Disconnectthebattery,negative(black)leadfirst.

3. Drainthecoolantasdescribedearlier.

4. Turnthe steeringtoleftorrightfulllock.

5. Disconnectthecoolanthosesfromthewaterpump.

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1. Bottomradiatorhose

2. Pumpoutlethose

3. Waterpump

6. Releasethetwolowerboltsthatsecurethewaterpumptothecrankcase.

Note:

• Thethird,upperboltis thedrainplugandalsoholdsthewaterpumptogether.

Withdrawthewater pump.

• ServiceManual-RocketIll

12.7

Inspection

1. Removethepumpoutercovertocheckforcorrosionand scalebuild-uparoundtheimpellorandinthepumpbody.Renewifnecessary.

2. Checkthewaterpumpshaftandshaftbearingsforsideandendfloat.Cleanorrenewifnecessary.

3. Checkthewater pumpglandforsignsofleakage.Renewthepumpifleakageisevident.

Installation

1. Replacethewaterpump'O'ringseal.

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1.'O'ringseal

2. Alignthedriveslotinthewaterpumpwiththedrivebladeontheoilpumpshaft(insidethecrankcase).

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Note:

• Thewaterpumpwillnotengagefullyintothecrankcaseunlessthedriveslotandbladearealignedandengaged.

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1. Waterpumpslot

2. Oilpumpshaft,driveblade

3. Fitthepumpand tightenthefixingsto10Nm.

4. Refitthehosestothewaterpumpandtightentheclips.

5. Reconnectthebattery,positive(red)leadfirst.

6. Refittherider'sseat.

7. Refillthecoolingsystemasdescribedonpage

12.7.

8. ServiceManual-RocketIll

CoolantPressureCap

Inspection

Thermostat

Removal

1. Removetherider'sseat.

2. Disconnectthebattery,negative{black)leadfirst.

3. Drainthe coolantasdescribedonpage12.6.

1. Removethepressurecapasdescribedinthecoolantdrainsection onpage12.6.

2. Checkconditionoftheupperandlowersealsofthecoolantpressurecap.

1.LowerSeal

2. UpperSeal

3. SpringNote:

   • If there isany signof damage ordeteriorationreplacethecap.

3. Pressuretestthecaptotheblowoffpressureof

1.2barusingproprietarytools.Ifthecapopensatalowerpressureorfailstoopenat1.2bar,replacethecap.

3. Refitthepressurecapasdescribedinthecoolantfillsectiononpage12.7.

Donotremovethecoolantpressurecapwhentheengineishot.Whentheengineishot,thecoolantinsidetheradiatorishotandalsounderpressure.Contactwithhotcoolantwillcausescaldsandskindamage.

4.Disconnectthetopand bypasshoses atthethermostathousing.

2

/

1.Tophose

2.Bypasshose

5. Releasethefixingssecuringthethermostathousingtothecylinderhead.

6. Withdraw thehousingandcollectthethermostat.

ServiceManual-RocketIll

12.9

Inspection

1. Inspectthethermostatatroomtemperature.Ifthevalveisopen,thethermostatmustbereplaced.

2. Tocheckthevalveopeningtemperature,suspendthethermostatinacontainerofwatertogetherwithathermometer.Raisethetemperatureofthewateruntilthethermostatopens.ThethermostatshouldstarttoopenatB8°C+/-5°C.

3. Ifthetemperatureatwhichthermostatopeningtakesplaceisincorrect,replacethethermostat.

Installation

1.Cleanthematingsurfacesofthecylinderheadandthermostathousing.

2.Locatethethermostatintotheheadwiththejigglepin15degreestotheleftofthefullyuprightposition.

1.Thermostat

2.Jigglepin

3. Rotatethethermostatuntilthejigglepinisinthefullyuprightposition.

Note:

• Whencorrectlypositioned,thethermostatwillfitsnuglyintothehead,thejigglepinwillbeinthetwelve0-clockpositionandthethermostatwillnotturnany furtherclockwise.

4. Positionanew0-ringtothethermostathousingandseatintothegroove.

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1.0-ring/groove

5. Locatethethermostathousingtothehead,ensuringthatthe0-ring doesnotbecomedetached.Tightenthefixingsto4Nm.

6. Reconnect the tophoseandsecurewiththehoseclip

7. Reconnectthebattery,positive(red)leadfirst.

8. Refittherider'sseat.

9. Refillthecoolingsystemasdescribedonpage

12.7.