Injector Resistance Connections to Injector

Meter (+) Meter (–)

#1: W/R ←→ BL/R Terminal

#2: W/R ←→ BL/G Terminal

Standard: About 11.7 ~ 12.3 Ω at 20°C (68°F)

If the reading is out of the range, perform the “Injector Unit Test”.

If the reading is normal, perform the “Injector Unit Test” for confirmation.

 

 

Injector Unit Test

• Use two leads [A] and the same test light set [B] as in “Injector Signal Test”.

CAUTION

Be sure to connect the bulb in series. The bulb works as a current limiter to protect the solenoid in the injector from excessive current.

Rating of Bulb [C]: 12 V × (3 ~ 3.4) W 12 V Battery [D]

• Connect the test light set to the injector [E] as shown.

• Open and connect [F] the end of the lead to the battery

(–) terminal repeatedly. The injector should click.

If the injector does not click, replace the injector.

If the injector clicks, check the wiring again. If the wiring is good, replace the injector (may be clogged) or ECU.

Injector Fuel Line Inspection

• Remove:

Fuel Tank (see Fuel Tank Removal)

Left Center Fairing (see Center Fairing Removal in the Frame chapter)

• Be sure to place a piece of cloth around the fuel hose joint

and the delivery pipe.

• Insert a minus screw driver [A] into the slit on the joint lock [B].

• Turn the driver to disconnect the joint lock.

• Pull the fuel hose joint [C] out of the delivery pipe.

• Check the injector fuel line for leakage as follows.

○Connect a commercially available vacuum/pressure

pump [A] to the nipple of the delivery pipe [B] with a

high-pressure fuel hose [C] (both ends connected with the clamps [D]) as shown.

Torque - Fuel Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)

○Apply soap and water solution to the areas [E] as shown.

○Watching the pressure gauge, squeeze the pump lever

[F], and build up the pressure until the pressure reaches

the maximum pressure.

CAUTION

During pressure testing, do not exceed the maxi- mum pressure for which the system is designed.

Injector Fuel Line Maximum Pressure Standard: 333 kPa (3.4 kgf/cm², 48 psi)

 

• Watch the gauge for at least 6 seconds.

If the pressure holds steady, the system is good.

If the pressure drops at once or if bubbles are found in the area, the line is leaking. Replace the delivery pipe, injectors and related parts.

○Repeat the leak test, and check the fuel line for no leak-

age.

• Install the pump outlet hose (see Fuel Tank Installation).

• Run the hoses correctly (see Cable, Wire, and Hose Rout-

ing section in the Appendix chapter).

Fuel Injector Circuit

1. ECU

2. Fuel Injectors

3. Water-proof Joint C

4. Engine Stop Switch

5. Ignition Switch

6. Ignition Fuse 10 A

7. Fuel Pump Relay (for fuel pump and injectors)

8. Relay Box

9. Main Fuse 30 A

10. Battery

11. Frame Ground

12. Joint Connector

 

 

Throttle Grip and Cables

Throttle Grip Free Play Inspection

• Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter.

Throttle Grip Free Play Adjustment

• Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter.

Throttle Cable Installation

• Install the throttle cables in accordance with Cable, Wire, and Hose Routing section in the Appendix chapter.

• Install the lower ends of the throttle cables in the cable

bracket on the throttle body assy after installing the upper

ends of the throttle cables in the grip.

WARNING

Operation with incorrectly routed or improperly ad- justed cables could result in an unsafe riding con- dition.

• After installation, adjust each cable properly.

 

 

Throttle Cable Lubrication

• Refer to the Chassis Parts Lubrication in the Periodic Maintenance chapter.

 

Idle Speed Inspection

• Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter.

Engine Vacuum Synchronization Inspection/Ad- justment

• Refer to the Engine Vacuum Synchronization Inspection

in the Periodic Maintenance chapter.

High Altitude Performance Adjustment

• Any modification is not necessary in this model since the inlet air pressure sensor senses inlet air pressure

change due to high altitude and the ECU compensates the change.

WARNING

Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Disconnect the battery (–) cable ter- minal. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Be prepared for fuel spillage: any spilled fuel must be completely wiped up immediately.

Throttle Body Assy Removal

• Remove:

Air Cleaner Housing (see Air Cleaner Housing Removal)

Center Fairings (see Center Fairing Removal in the Frame chapter)

• Disconnect:

Main Throttle Sensor Connector [A]

Fuel Hose Lower End [B] Vacuum Hose [C]

 

 

• Disconnect:

#1, #2 Injector Connector [A]

Subthrottle Sensor Connector [B] Subthrottle Sensor Actuator Connector [C]

• Loosen:

Holder and Duct Clamp Bolts

 

 

Throttle Body Assy

• Loosen the locknut and screw in the throttle cable adjuster fully to give the cables plenty of play.

• Remove the right switch housing and take out the acceler-

ator cable upper end [A] and the decelerator cable upper

end [B].

 

 

• Remove the throttle cable lower ends [A] from the throttle pulley.

 

• After removing the throttle body assy, stuff pieces of lint

CAUTION

If dirt gets into the engine, excessive engine wear and possible engine damage will occur.

-free, clean cloth into the throttle body holders.

 

Throttle Body Assy Installation

• Install the holder clamp bolts [A] in the direction shown with each bolt heads [B], facing outwards.

 

 

• Install the air cleaner duct clamp screws [A] so that their screw heads [B] face the right.

• Run the vacuum hose (see Cable, Wire, and Hose Rout-

ing section in the Appendix chapter).

 

 

• Fit the accelerator cable end [A] and the decelerator cable end [B] into the throttle pulley.

WARNING

Fuel spilled from the carburetors is hazardous.

• Check fuel leakage from the throttle body assy.

 

 

• Apply a thin coating of grease to the throttle cable upper ends.

• Install the upper ends of the throttle cables in the grip.

• Fit the projection [A] of the right switch housing into the

hole [B] of the handlebar.

• Turn the throttle grip and make sure that the throttle valves move smoothly and return by spring force.

• Check the throttle grip free play (see Throttle Control Sys-

WARNING

Operation with an incorrectly routed cable could re- sult in an unsafe riding condition.

tem Inspection in the Periodic Maintenance chapter).

• Adjust:

Throttle Grip Free Play (see Throttle Control System In-

spection in the Periodic Maintenance chapter)

Idle Speed (see Idle Speed Adjustment in the Periodic Maintenance chapter)

CAUTION

Do not remove, disassemble or adjust the main throttle sensor [A], subthrottle sensor [B], sub- throttle valve actuator [C], throttle link mechanism [D] and throttle body assy [E], because they are adjusted or set at the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy.

Throttle Body Assy Disassembly

• Remove the throttle body assy (see Throttle Body Assy Removal).

CAUTION

Never drop the throttle body assy, especially on a hard surface. Such a shock to the body assy can damage it.

 

 

Throttle Body Assy

• Remove: Screws [A]

Delivery Pipe [B] Fuel Injectors [C]

 

Throttle Body Assy Assembly

○Replace the O-rings [A] and seals [B] with the new ones.

• Before assembling, blow away dirt or dust from the throttle body and delivery pipe by applying compressed air.

• Apply engine oil to the new O-rings of each injector [C],

insert them into the delivery pipe and confirm whether the

injectors turn smoothly or not.

• Install the injectors along with the delivery pipe assy into the throttle bodies.

 

• Install the throttle body assy (see Throttle Body Assy In- stallation).

 

 

Air Cleaner

Air Cleaner Element Removal/Installation

• Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter.

Air Cleaner Element Inspection

• Remove the air cleaner element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter).

• Visually check the element [A] for tears or breaks.

If the element has any tears or breaks, replace the ele-

ment.

 

Air Cleaner Oil Draining

A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part.

• Remove the left center fairing (see Center Fairing Re-

moval in the Frame chapter).

• Visually check the drain hose [A] if the water or oil accu- mulates.

WARNING

Be sure to reinstall the plug in the drain hose after draining. Oil on tires will make them slippery and can cause an accident and injury.

If any water or oil accumulates in the hose, remove the plug [B] from the drain hose and drain it.

Air Cleaner Housing Removal

• Remove:

Fuel Tank (see Fuel Tank Removal)

Hose (Disconnect) [A]

Inlet Air Temperature Sensor Connector [B] Screws [C]

Cover [D]

 

• Disconnect the breather hose [A] on the upper crankcase.

 

 

Air Cleaner

• Unscrew the bolts [A] and remove the air cleaner housing [B].

 

Air Cleaner Housing Installation

• Install the clamp on the hose [A] so that its pinch heads [B] face the right.

• Install the clamp on the breather hose [C] so that its pinch

heads [D] face the front.

 

Fuel Tank Removal

WARNING

Gasoline is extremely flammable and can be explo- sive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

• Turn the ignition switch and engine stop switch OFF.

• Wait until the engine cools down.

• Open the fuel tank cap [A] to lower the pressure in the

tank.

○During tank removal, keep the tank cap open to release

pressure in the tank. This makes fuel spillage less.

 

 

• Remove:

Seat (see Seat Removal in the Frame chapter)

Side Covers (see Side Cover Removal in the Frame chapter)

Fuel Tank Bolts [A]

 

 

• Draw the fuel out from the fuel tank with a commercially available pump [A].

○Use a soft plastic hose [B] as a pump inlet hose in order

to insert the hose smoothly.

○Put the hose through the fill opening [C] into the tank and

draw the fuel out.

WARNING

The fuel could not be removed completely from the fuel tank. Be careful for remained fuel spillage.

Front [D]

 

• Disconnect the fuel pump lead connector [A] and the tube [B].

• Remove:

Fuel Return Hose [C] (Red, California Model)

Fuel Tank Breather Hose [D] (Blue, California Model)

 

 

• Be sure to place a piece of cloth [A] around the fuel hose joint.

• Insert a minus screw driver [B] into the slit [C]on the joint

lock.

 

 

• Turn [A] the driver to disconnect the joint lock [B].

CAUTION

When removing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump. The pipe made from resin could be damaged.

• Pull [C] the fuel hose joint out [D] of the outlet pipe.

 

WARNING

Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.

 

 

• Close the fuel tank cap.

• Remove the fuel tank, and place it on a flat surface.

○Do not apply the load to the fuel pump outlet portion [A]

especially the outlet pipe made from resin.

CAUTION

For California model, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one.

• For California model, note the following.

 

WARNING

For California model, be careful not to spill the gasoline through the return hose. Spilled fuel is hazardous.

○Besure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal.

If liquid or gasoline flows into the breather hose, remove the hose and blow it clean with compressed air.

○Be careful of fuel spillage from the fuel tank since fuel still

WARNING

Store the fuel tank in an area which is well -ventilated and free from any source of flame or sparks. Do not smoke in this area. Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage.

remains in the fuel tank and fuel pump.

Fuel Tank Installation

• Note the above WARNING (see Fuel Tank Removal).

• Route the hoses correctly (see Cable, Wire, and Hose

Routing in the Appendix chapter).

• Check that the rubber dampers [A] are on the frame and the fuel tank.

 

 

• Check that the dampers [A] are in place on the fuel tank as well.

If the dampers are damaged or deteriorated, replace them.

 

 

• Be sure that the trim seal [A] is on the fuel tank. Reverse Side of Fuel Tank [B]

Side Cover [C]

Approx. 17 mm (0.67 in.) [D] Front [E]

• For California model, note the following.

○To prevent the gasoline from flowing into or out of the

canister, hold the separator perpendicular to the ground.

○Connect the hoses according to the diagram of the sys-

tem (see Cable, Wire, and Hose Routing section in the

Appendix chapter). Make sure they do not get pinched or kinked.

○Route hoses with a minimum of bending so that the air or

vapor will not be obstructed.

CAUTION

When installing the fuel hose joint, do not apply strong force to the outlet pipe on the fuel pump. The pipe made from resin could be damaged.

• Insert [A] the fuel hose joint [B] straight onto the delivery pipe until the hose joint clicks.

• Push [C] the joint lock [D].

• Push and pull [A] the hose joint [B] back and forth more than two times and make sure it is locked and doesn’t

come off.

WARNING

Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak.

If it comes off, reinstall the hose joint.

• Connect the fuel pump and the fuel level sensor connec- tors and the battery (–) cable terminal.

Fuel Tank and Cap Inspection

• Visually inspect the gasket [A] on the tank cap for any damage.

Replace the gasket if it is damaged.

• Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank is not clogged. check the tank cap

breather also.

CAUTION

Do not apply compressed air to the air vent holes [D] in the tank cap. This could cause damage and clogging of the labyrinth in the cap.

If they are clogged, remove the tank and drain it, and then blow the breather free with compressed air.

 

 

WARNING

Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger or highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank.

Fuel Tank Cleaning

• Remove the fuel tank (see Fuel Tank Removal).

• Remove the fuel pump inlet hose and the fuel pump (see

Fuel Pump Removal).

• Pour some high-flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits.

• Draw the solvent out of the fuel tank.

• Dry the tank with compressed air.

• Install the fuel pump (see Fuel Pump Installation).

• Install the fuel tank (see Fuel Tank Installation).

 

 

Evaporative Emission Control System (California Model)

The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.

Parts Removal/Installation

WARNING

Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

CAUTION

If gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capac- ity is greatly reduced. If the canister does become contaminated, replace it with a new one.

• To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground.

• Connect the hoses according to the diagram of the sys-

tem (see Cable, Wire, and Hose Routing section in the

Appendix chapter). Make sure they do not get pinched or kinked.

Hose Inspection

• Refer to the Evaporative Emission Control System In- spection in the Periodic Maintenance chapter.

Separator Inspection

• Refer to the Evaporative Emission Control System In- spection in the Periodic Maintenance chapter.

Separator [A]

 

 

Evaporative Emission Control System (California Model)

Separator Operation Test

WARNING

Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

• Connect the hoses to the separator, and install the sepa- rator on the motorcycle.

• Disconnect the breather hose from the separator, and in-

ject about 20 mL (0.68 US oz.) of gasoline [A] into the

separator [B] through the hose fitting.

• Disconnect the fuel return hose [C] from the fuel tank [D].

• Run the open end of the return hose into the container

and hold it level with the tank top [E].

• Start the engine, and let it idle.

If the gasoline in the separator comes out of the hose, the

separator works well. If it does not, replace the separator with a new one.

Canister Inspection

• Refer to the Evaporative Emission Control System In- spection in the Periodic Maintenance chapter.

NOTE

○The canister [A] is designed to work well through the

motorcycle’s life without any maintenance if it is used

under normal conditions.

 

 

 

 

 

Cooling System

Table of Contents

Exploded View........................................................................................................................ 4-2

Coolant Flow Chart................................................................................................................. 4-4

Specifications......................................................................................................................... 4-6

Special Tools.......................................................................................................................... 4-7

Coolant................................................................................................................................... 4-8

Coolant Deterioration Inspection....................................................................................... 4-8 4

Coolant Level Inspection................................................................................................... 4-8

Coolant Draining............................................................................................................... 4-8

Coolant Filling................................................................................................................... 4-8

Pressure Testing............................................................................................................... 4-8

Cooling System Flushing.................................................................................................. 4-9

Coolant Reserve Tank Removal/Installation..................................................................... 4-9

Water Pump............................................................................................................................ 4-10

Water Pump Removal....................................................................................................... 4-10

Water Pump Installation.................................................................................................... 4-10

Mechanical Seal Inspection.............................................................................................. 4-11

Water Pump Housing Disassembly.................................................................................. 4-11

Water Pump Housing Assembly....................................................................................... 4-11

Impeller Assembly............................................................................................................. 4-12

Pump Impeller Inspection................................................................................................. 4-12

Radiator.................................................................................................................................. 4-13

Radiator and Radiator Fan Removal................................................................................ 4-13

Radiator and Radiator Fan Installation............................................................................. 4-14

Radiator Inspection........................................................................................................... 4-14

Radiator Cap Inspection................................................................................................... 4-14

Radiator Filler Neck Inspection......................................................................................... 4-15

Thermostat............................................................................................................................. 4-16

Thermostat Removal......................................................................................................... 4-16

Thermostat Installation...................................................................................................... 4-16

Thermostat Inspection...................................................................................................... 4-16

Hose and Pipes...................................................................................................................... 4-18

Hose Installation............................................................................................................... 4-18

Hose Inspection................................................................................................................ 4-18

Water Temperature Sensor.................................................................................................... 4-19

Water Temperature Sensor Removal/Installation............................................................. 4-19

Water Temperature Sensor Inspection............................................................................. 4-19

Exploded View

 

Exploded View

No.	Fastener	Torque	Remarks
N·m	kgf·m	ft·lb
	Radiator Hose Clamp Screws	2.0	0.20	17 in·lb
	Water Pump Impeller Bolt	9.8	1.0	87 in·lb
	Water Pump Cover Bolts	9.8	1.0	87 in·lb
	Water Pump Drain Bolt	7.0	0.70	62 in·lb
	Thermostat Housing Bolts	9.8	1.0	87 in·lb
	Water Temperature Sensor		1.2	106 in·lb
	Baffle Plate Bolts	5.9	0.60	52 in·lb

8. Reserve Tank

9. Baffle Plate

10. Cylinder Head Cover

11. Thermostat

12. Water Pump Impeller

13. Mechanical Seal G: Apply grease.

HG: Apply high-temperature grease. R: Replacement Parts

 

 

Coolant Flow Chart

 

Coolant Flow Chart

Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates.

The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level. When coolant temperature is below 80.5 ~ 83.5°C (177 ~ 182°F), the thermostat closes so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly. When coolant temperature is more than 80.5 ~ 83.5°C, the thermostat opens and the coolant flows.

When the coolant temperature goes up beyond 93 ~ 103°C (199 ~ 217°F), the radiator fan relay conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator. When the temperature is below 91°C (196°F) ~ temperature less than ON temperature, the fan relay opens and the radiator fan stops.

In this way, this system controls the engine temperature within narrow limits where the engine op- erates most efficiently even if the engine load varies.

The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating. As the engine warms up, the coolant in the radiator and the water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank.

The radiator cap has two valves. One is a pressure valve which holds the pressure in the system when the engine is running. When the pressure exceeds 112.3 ~ 141.7 kPa (1.15 ~ 1.45 kgf/cm²,

16.3 ~ 20.5 psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure escapes, the valve closes, and keeps the pressure at 112.3 ~ 141.7 kPa (1.15 ~ 1.45 kgf/cm², 16.3 ~ 20.5 psi). When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator.

 

 

Specifications

Item	Standard
Coolant Provided when Shipping Type (Recommended) Color Mixed Ratio Freezing Point Total Amount	Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Green Soft water 50%, coolant 50% −35°C (−31°F) 1.2 L (1.3 US qt) (reserve tank full level, including radiator and engine)
Radiator Cap Relief Pressure	112.3 ~ 141.7 kPa (1.15 ~ 1.45 kgf/cm², 16.3 ~ 20.5 psi)
Thermostat Valve Opening Temperature Valve Full Opening Lift	80.5 ~ 83.5°C (177 ~ 182°F) 8 mm (0.31 in.) or more at 95°C (203°F)

 

Special Tools

Bearing Driver Set: 57001-1129

Oil Seal Driver: 57001-1660

 

Coolant

Coolant Deterioration Inspection

• Remove the right center fairing (see Center Fairing Re- moval in the Frame chapter).

• Visually inspect the coolant [A] in the reserve tank.

If whitish cotton-like wafts are observed, aluminum parts

in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.

If the coolant gives off an abnormal smell, check for a cooling system leak. It may be caused by exhaust gas leaking into the cooling system.

Coolant Level Inspection

• Refer to the Coolant Level in the Periodic Maintenance chapter.

Coolant Draining

• Refer to the Coolant Change in the Periodic Maintenance chapter.

Coolant Filling

• Refer to the Coolant Change in the Periodic Maintenance chapter.

Pressure Testing

• Remove the reserve tank (see Coolant Change in the Pe- riodic Maintenance chapter).

• Remove the radiator cap, and install a cooling system

pressure tester [A] on the filler neck [B].

NOTE

○Wet the cap sealing surfaces with water or coolant to

prevent pressure leaks.

CAUTION

During pressure testing, do not exceed the pres- sure for which the system is designed. The maxi- mum pressure is 141.7 kPa (1.45 kgf/cm², 20.5 psi).

• Build up pressure in the system carefully until the pres- sure reaches 141.7 kPa (1.45 kgf/cm², 20.5 psi).

• Watch the gauge for at least 6 seconds.

If the pressure holds steady, the system is all right.

If the pressure drops and no external source is found, check for internal leaks. Droplets in the engine oil indicate internal leakage. Check the cylinder head gasket and the water pump.

• Remove the pressure tester, replenish the coolant, and

install the radiator cap.

 

 

Coolant

Cooling System Flushing

Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the effi- ciency of the cooling system.

• Drain the cooling system (see Coolant Change in the Pe-

riodic Maintenance chapter).

CAUTION

Do not use a flushing compound which is harmful to the aluminum engine and radiator. Carefully follow the instructions supplied by the manufacturer of the cleaning product.

• Fill the cooling system with fresh water mixed with a flush- ing compound.

• Warm up the engine, and run it at normal operating tem- perature for about ten minutes.

• Stop the engine, and drain the cooling system.

• Fill the system with fresh water.

• Warm up the engine and drain the system.

• Repeat the previous two steps once more.

• Fill the system with a permanent type coolant and bleed

the air from the system (see Coolant Change in the Peri-

odic Maintenance chapter).

Coolant Reserve Tank Removal/Installation

• The coolant reserve tank is removed and installed dur- ing coolant change (see Coolant Change in the Periodic

Maintenance chapter).

 

Water Pump Removal

• Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).

• Loosen the clamp and remove the radiator hose [A] from

the water pump cover [B].

• Remove the water pump cover bolts [C].

 

 

• Shift the transmission into 1st gear.

• While applying the rear brake, remove the water pump

impeller bolt [A].

• Remove: Impeller [B]

Water Pump Housing [C]

 

Water Pump Installation

• When installing the water pump impeller bolt, shift the transmission into 1st gear and apply the rear brake.

• Replace the O-rings [A] on the water pump housing with

new ones and apply grease them.

• Apply high-temperature grease to the lips of the water pump housing oil seal [B].

 

• Be sure that the dowel pin [A] is in position.

• Install the water pump housing.

• Tighten:

Torque - Water Pump Impeller Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

• Replace the O-ring [A] on the water pump cover with a new one and grease it.

 

 

Water Pump

• Install the water pump cover, being careful of the two dowel pins [A].

Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

Mechanical Seal Inspection

• Visually inspect the mechanical seal.

If any one of the parts is damaged, replace the mechani-

cal seal as a unit.

○The sealing seat and rubber seal may be removed easily

by hand.

Impeller Sealing Seat Surface [A] Rubber Seal [B]

Mechanical Seal Diaphragm [C]

 

CAUTION

Be careful not to damage the sealing surface of the mechanical seal.

Water Pump Housing Disassembly

• Take the oil seal [A] out of the housing [B] with a hook [C].

 

• Press the mechanical seal [A] out of the housing with a bearing driver [B].