4-6
RADIATOR
HANDLING NOTE
Do not remove the radiator cap
when the engine and radiator are
hot. Scalding hot fluid and steam
may be blown out under pressure,
which could cause serious injury.
When the engine has cooled, open
the radiator cap by the following
procedure:
Place a thick rag, like a towel, over
the radiator cap, slowly rotate the
cap counterclockwise to the de-
tent. This procedure allows any re-
sidual pressure to escape. When
the hissing sound has stopped,
press down on the cap while turn-
ing counterclockwise and remove
it.
CHECKING THE RADIATOR
1. Inspect:
• Radiator core "1"
Obstruction
→Blow out with com-
pressed air through rear of the ra-
diator.
Bent fin
→Repair/replace.
INSTALLING THE RADIATOR
1. Install:
• Pipe 1 "1"
• Radiator hose 1 "2"
• Pipe 2 "3"
• Radiator hose 3 "4"
• Radiator hose 4 "5"2. Install:
• Radiator hose 2 "1"
• Left radiator "2"
3. Install:
• Radiator breather hose "1"
• Right radiator "2"
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2.
4. Install:
• Radiator guard "1"
First fit the inner hook portion "a" and
then the outer one "b" onto the radia-
tor.
Pipe 1:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Radiator hose 1:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Pipe 2:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Radiator hose 3:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Radiator hose 4:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Radiator hose 2:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Left radiator:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Right radiator:
10 Nm (1.0 m•kg, 7.2
ft•lb)
4-19
CYLINDER HEAD
CYLINDER HEAD
REMOVING THE CYLINDER HEAD
Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•lb) in the proper tightening sequence, remove and retighten the
cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper tightening sequence, and then tighten the cylinder head bolts
further to reach the specified angle 180° in the proper tightening sequence.
Order Part name Q'ty Remarks
Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE
COVERS" section.
Exhaust pipe and silencerRefer to "EXHAUST PIPE AND SILENCER"
section.
Radiator Refer to "RADIATOR" section
Carburetor Refer to "CARBURETOR" section.
Camshaft Refer to "CAMSHAFTS" section.
1Bolt 2
2* Bolt 4 Refer to NOTE.
3 Cylinder head 1
4 Gasket 1
5 Timing chain guard (exhaust side) 1
4-49
ENGINE REMOVAL
ENGINE REMOVAL
REMOVING THE ENGINE
Order Part name Q'ty Remarks
Hold the machine by placing the suitable stand
under the frame.Refer to "HANDLING NOTE".
Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE
COVERS" section.
Rear shock absorber Refer to "REAR SHOCK ABSORBER" sec-
tion in the CHAPTER 5.
Carburetor Refer to "CARBURETOR" section.
Exhaust pipe and silencer Refer to "EXHAUST PIPE AND SILENCER"
section.
Clutch cable Disconnect at the engine side.
Radiator Refer to "RADIATOR" section.
Shift pedalRefer to "KICK SHAFT AND SHIFT SHAFT"
section.
Cylinder head breather hose Refer to "CAMSHAFTS" section.
Drain the engine oil.Refer to "CHANGING THE ENGINE OIL"
section in the CHAPTER 3.
Ignition coil
Disconnect the CDI magneto lead.
