COOLING AND LUBRICATION SYSTEM 7-1
COOLING AND LUBRICATION SYSTEM
CONTENTS
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ENGINE COOLANT |
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COOLING CIRCUIT ..................................................................................... |
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COOLING CIRCUIT ........................................................INSPECTION |
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RADIATOR AND WATER ..............................................................HOSES |
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RADIATOR REMOVAL ......................................................................... |
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RADIATOR CAP .............................................................INSPECTION |
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RADIATOR INSPECTION .........................................AND CLEANING |
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RADIATOR INSTALLATION................................................................. |
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WATER HOSE INSPECTION................................................................ |
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COOLING FAN............................................................................................. |
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REMOVAL ............................................................................................. |
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INSPECTION ......................................................................................... |
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E |
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INSTALLATION |
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L |
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COOLING FAN RELAY INSPECTION |
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ECT SENSOR .............................................................................................. |
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P |
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REMOVAL |
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INSPECTION ......................................................................................... |
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M |
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INSTALLATION |
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A |
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THERMOSTAT |
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REMOVAL ............................................................................................. |
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S |
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INSPECTION .........................................................................................
INSTALLATION.....................................................................................
WATER PUMP .............................................................................................
REMOVAL AND DISASSEMBLY .........................................................
INSPECTION .........................................................................................
REASSEMBLY AND INSTALLATION ..................................................
LUBRICATION SYSTEM .............................................................................
OIL COOLER.........................................................................................
OIL PRESSURE ....................................................................................
OIL FILTER............................................................................................
OIL PRESSURE REGULATOR.............................................................
OIL STRAINER......................................................................................
OIL JET..................................................................................................
OIL PUMP..............................................................................................
OIL PRESSURE SWITCH .....................................................................
ENGINE LUBRICATION SYSTEM CHART ..........................................
ENGINE LUBRICATION SYSTEM........................................................
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7-10 |
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7-11 |
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7-11 |
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7-13 |
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7-14 |
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7-17 |
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7-17 |
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7-18 |
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7-18 |
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7-18 |
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7-18 |
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7-18 |
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7-18 |
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7-18 |
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7-19 |
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7-20 |
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7-2 COOLING AND LUBRICATION SYSTEM
ENGINE COOLANT
At the time of manufacture, the cooling system is filled with a 50:50 mixture of distilled water and ethylene glycol anti-freeze. This 50:50 mixture will provide the optimum corrosion protection and excellent heat protection, and will protect the cooling system from freezing at temperatures above –31 °C (–24 °F).
If the motorcycle is to be exposed to temperatures below –31 °C (–24 °F), this mixing ratio should be increased up to 55% or 60% according to the figure.
Anti-freeze density |
Freezing point |
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50% |
–30 °C (–24 °F) |
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55% |
–40 °C (–44 °F) |
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60% |
–55 °C (–67 °F) |
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*Use a high quality ethylene glycol base anti-freeze, mixed with distilled water. Do not mix an alcohol base anti-freeze and different brands of anti-freeze.
*Do not put in 60% and more anti-freeze or 50% and less. (Refer to below figure.)
*Do not use a radiator anti-leak additive.
50% Engine coolant including reserve tank capacity |
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E |
Anti-freeze |
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1 350 ml (2.9/2.4 US/lmp.pt) |
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Water |
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1 350 ml (2.9/2.4 US/lmp.pt) |
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P |
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(˚F) |
(˚C) |
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M |
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32 |
0 |
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(˚F) (˚C) |
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(kgf/cm²) |
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14 |
–10 |
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302 150 |
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–4 |
–20 |
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A |
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284 140 |
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–22 |
–30 |
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pointFreezing |
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pointBoiling |
266 130 |
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–40 |
–40 |
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–58 |
–50 |
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248 120 |
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–76 |
–60 |
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230 110 |
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–94 |
–70 |
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212 100 |
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1.5 |
pressure |
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0.9 |
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0.5 |
Gauge |
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20 |
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60 |
80 |
100 |
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10 |
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Density (%) |
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Density (%) |
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Fig. 1 Engine coolant density-freezing point curve
Fig. 2 Engine coolant density-boiling point curve
*You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.
*The engine must be cool before servicing the cooling system.
*Coolant is harmful;
•If it comes in contact with skin or eyes, flush with water.
•If swallowed accidentally, induce vomiting and call physician immediately.
•Keep it away from children.
COOLING AND LUBRICATION SYSTEM 7-3
COOLING CIRCUIT
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RESERVOIR |
THERMOSTAT |
CYLINDER HEAD |
ECT SENSOR |
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TANK |
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CYLINDER |
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RADIATOR |
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WATER |
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PUMP |
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Oil cooler |
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COOLING CIRCUIT INSPECTION
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Before removing the radiator and draining the engine coolant, |
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inspect the cooling circuit for tightness. |
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• Remove the right under cowling. ( 8-5) |
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• Remove the radiator cap 1 and connect the tester 2 to the |
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filler. |
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M |
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Do not remove the radiator cap when the engine is |
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hot. |
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•Give a pressure of about 120 kPa (1.2 kgf/cm², 17 psi) and see if the system holds this pressure for 10 seconds.
•If the pressure should fall during this 10-second interval, it means that there is a leaking point in the system. In such a case, inspect the entire system and replace the leaking component or part.
When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant.
Do not allow the pressure to exceed the radiator cap release pressure, or the radiator can be damaged.
7-4 COOLING AND LUBRICATION SYSTEM
RADIATOR AND WATER HOSES
RADIATOR REMOVAL
• Remove the under cowlings. ( 8-5)
• Drain the engine coolant. ( 2-17)
• Remove the radiator assembly. ( 3-4)
• Remove the reservoir tank 1, cooling fan 2 from the radiator.
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RADIATOR CAP INSPECTION |
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• Fit the cap 1 to the radiator cap tester 2. |
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• Build up pressure slowly by operating the tester. ake sure |
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that the pressure build-up stops at 93 – 123MkPa (0.93 – 1.23 |
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kgf/cm2, 13.2 – 17.5 psi) and that, with the tester held stand- |
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still, the cap is capable of holding that pressure for at least 10 |
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seconds. |
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• Replace the cap if it is found not to satisfy either of these two |
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requirements. |
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Radiator cap valve opening pressure Standard: 108 – 137 kPa
(1.1 – 1.4 kgf/cm2, 15.4 – 19.5 psi)
RADIATOR INSPECTION AND CLEANING
Road dirt or trash stuck on the fins must be removed.
Use of compressed air is recommended for this cleaning.
COOLING AND LUBRICATION SYSTEM 7-5
Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver.
RADIATOR INSTALLATION
• Install the cooling fan.
Cooling fan mounting bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft)
•Install the radiator.
•Route the radiator hoses properly. ( 10-24)
•Pour engine coolant. ( 2-17)
•Bleed air from the cooling circuit. ( 2-18)
•Install the under cowlings. ( 8-5)
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WATER HOSE INSPECTION |
L |
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P |
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• Remove the under cowlings. ( 8-5) |
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• Lift and support the fuel tank. ( 5-3) |
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Any water hose found in a cracked condition or flattened must |
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be replaced. |
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Any leakage from the connectingAsection should be corrected by |
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proper tightening. |
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