Page 250 of 762
3 - 9
INSP
ADJ
COOLING SYSTEM INSPECTION
3. Inspect:
lPressure
Impossible to maintain the specified
pressure for 10 seconds ® Replace.
EC357002
COOLING SYSTEM INSPECTION
1. Inspect:
lCoolant level
2. Attach:
lRadiator cap tester 1 and adapter 2
3. Apply the specified pressure.
NOTE:
lDo not apply pressure more than specified
pressure.
lRadiator should be filled fully.
Radiator cap tester:
YU-24460-01/90890-01325
Adapter:
YU-33984/90890-01352
Standard pressure:
180 kPa (1.8 kg/cm2, 25.6 psi)
4. Inspect:
lPressure
Impossible to maintain the specified
pressure for 10 seconds ® Repair.
lRadiator
lRadiator hose joint
Coolant leakage ® Repair or replace.
lRadiator hose
Swelling ® Replace.
Page 342 of 762
ENG
4 - 4
RADIATOR
EC450001
RADIATOR
Extent of removal:
1
Radiator removal
2
Coolant reservoir removal
Extent of removal Order Part name Q’ty Remarks
RADIATOR REMOVAL
Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Seat, fuel tank and side cover Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe Refer to “EXHAUST PIPE AND
SILENCER” section.
1 Engine guard (right) 1
2 Panel 2
3 Clamp 8
4 Radiator (right) 1
5 Hose 2 1
6 Hose 3 1
7 Hose 4 1
8 Pipe 2/O-ring 1/1
9 Radiator breather hose 1
10 Radiator (left) 1
1
Page 344 of 762
ENG
4 - 5
RADIATOR
Extent of removal Order Part name Q’ty Remarks
11 Hose 1 1
12 Pipe 1/O-ring 1/1
13 Coolant reservoir hose 1
14Coolant reservoir tank
1
2
1
Page 458 of 762
ENG
4 - 62
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)
Extent of removal:1 Oil filter removal2 Water pump removal
3 Crankcase cover (right) removal
Extent of removal Order Part name Q’ty Remarks
OIL FILTER, WATER PUMP
AND CRANKCASE COVER
(RIGHT) REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Exhaust pipe Refer to “EXHAUST PIPE AND
SILENCER” section.
Brake pedal Refer to “ENGINE REMOVAL” section.
Clutch cover Refer to “CLUTCH” section.
1 Oil filter cover 1
2 Oil filter 1
3 Coolant pipe 2 1
4 Water pump housing 1
5 Pin 2
6 Oil delivery pipe 1
1
2
3
Page 462 of 762
4 - 64
ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
REMOVAL POINTS
EC4G3110
Impeller shaft
1. Remove:
lImpeller 1
lPlain washer 2
lImpeller shaft 3
NOTE:
Hold the impeller shaft on its width across the
flats a with spanners, etc. and remove the
impeller.
EC4G3210
Oil seal
NOTE:
It is not necessary to disassemble the water
pump, unless there is an abnormality such as
excessive change in coolant level, discolora-
tion of coolant, or milky transmission oil.
1. Remove:
lBearing 1
lOil seal 2
INSPECTION
EC444200
Impeller shaft
1. Inspect:
lImpeller shaft 1
Bend/wear/damage ® Replace.
Fur deposits ® Clean.
Page 470 of 762
4 - 68
ENG
2. Install:
lWater pump housing 1
lBolt (water pump housing) 2
lPlain washer 3
lCoolant drain bolt 4
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:
lO-ring
lCoolant pipe 1
lBolt (coolant pipe) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
Oil filter
1. Install:
lOil filter 1
lO-ring 2
lOil filter cover 3
lBolt (oil filter cover)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
Page 662 of 762
5 - 59
CHASREAR SHOCK ABSORBER
EC580000
REAR SHOCK ABSORBER
Extent of removal:1 Rear shock absorber removal2 Rear shock absorber disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR SHOCK ABSORBER
REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Seat, fitting band and side covers Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
Silencer Refer to “EXHAUST PIPE AND
SILENCER” section in the CHAPTER 4.
Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Coolant reservoir tank Refer to “RADIATOR” section in the
CHAPTER 4.
1 Tail light connector 2
2 Band 2
3 Bolt (reservoir tank) 1
4 Clamp (air cleaner joint) 1 Only loosening.
5 Rear frame 1
6 Bolt (rear shock absorber-relay arm) 1Hold the swingarm.
7 Bolt (rear shock absorber-frame) 1
8 Rear shock absorber 1
12
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