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11. COOLING SYSTEM

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COOLING SYSTEM

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SCHEMATIC DRAWING ---------------------------------------------- 11- 1

SERVICE INFORMATION -------------------------------------------- 11- 2

TROUBLESHOOTING ------------------------------------------------- 11- 2

COOLING SYSTEM TESTING --------------------------------------- 11- 4

RADIATOR -------------------------------------------------------------- 11- 4

WATER PUMP ---------------------------------------------------------- 11- 8

THERMOSENSOR ------------------------------------------------------ 11-12

THERMOSTAT---------------------------------------------------------- 11-13

Summary of content (15 pages)

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1.
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11. COOLING SYSTEM SCHEMATIC DRAWING Torque: 1.0_ 11-1 1.
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11. COOLING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. • The engine must be cool before servicing the cooling system. When the coolant temperature is over 100℃ , never remove the radiator cap to release the pressure because the boiling coolant may cause danger. • Avoid spilling coolant on painted surfaces because the coolant will corrode the painted surfaces.
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11. COOLING SYSTEM SPECIFICATIONS Radiator cap relief pressure 0.9±0.15kg/cm_ 80±2℃ 90℃ 3.5_ 4.5mm Begins to open Full-open Valve lift Thermostat temperature 825cc Total system 1165cc Radiator: Reserve tank: 340cc Coolant capacity COOLANT GRAVITY Temp. ℃ Coolant concentration 5% 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 0 5 10 15 20 25 30 35 40 45 50 1.009 1.018 1.028 1.036 1.045 1.053 1.063 1.072 1.080 1.086 1.095 1.100 1.009 1.107 1.027 1.035 1.044 1.051 1.062 1.070 1.078 1.084 1.
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11. COOLING SYSTEM COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Install the radiator cap onto the radiator tester and apply specified pressure to it. It must hold specified pressure for at least six seconds. Radiator Tester ＊ Apply water to the cap sealing surface before testing. Radiator Cap Relief Pressure: 0.9±0.15kg/cm_ Radiator Cap Radiator Tester Install the radiator tester onto the radiator and apply specified pressure to it. It must hold specified pressure for at least six seconds.
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11. COOLING SYSTEM Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc., are clogging the radiator, wash them off. Carefully straighten any bent fins. RADIATOR REMOVAL Drain the coolant. (3-9) Remove the overflow tube clamp and disconnect the overflow tube. Overflow Tube Loosen the hose band and disconnect the upper hose from the radiator.
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11. COOLING SYSTEM Loosen the hose band and disconnect the lower hose from the radiator. Lower Hose Radiator Remove the four screws and the radiator. Screws Bolts RADIATOR BRACKET REMOVAL/ INSTALLATION Remove the two bolts to remove the radiator bracket. The installation sequence is the reverse of removal.
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11. COOLING SYSTEM Screws RADIATOR INSTALLATION Install the radiator on the radiator bracket with the four screws. Radiator . Upper Hose Connect the upper and lower hoses and secure them with hose bands. Lower Hose Install the heat screen. Connect the overflow tube and secure with the tube clamp.
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11. COOLING SYSTEM Screws Set the two tabs under the air duct into the grooves on the radiator lower part and then secure the radiator with the two screws. Fill the radiator with coolant. (3-12) After installation, check for coolant leaks. Air Duct Water Pump WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal.
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11. COOLING SYSTEM Bolts Remove the three bolts and the water pump cover, gasket and 1 dowel pins. Water Pump Cover Impeller Remove the three bolts attaching the right crankcase cover and the cover. Remove the water pump impeller. Inspect the mechanical (water) seal and inner bearing for wear or damage. Mechanical Seal ＊ The mechanical seal and inner bearing must be replace as a set.
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. COOLING SYSTEM Water Pump Assembly MECHANICAL S EAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the outer. Mechanical Seal (Water Seal) Drive in a new mechanical seal using a mechanical seal driver. ＊ Apply sealant to the right crankcase cover fitting surface of a new mechanical seal and then drive in the mechanical seal.
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11. COOLING SYSTEM WATER PUMP/IMPELLER INSTALLATION When the mechanical seal is replaced, a new shaft inside must be installed to the impeller. Install the impeller onto the water pump assembly. Torque: 1.0_ 1.4kg-m Mechanical Seal Impeller Disk water pump Bolts Install the one dowel pins and a new gasket. Install the water pump cover and tighten the 3 bolts. Torque: 0.8_ 1.2kg-m Bolts Install the right crankcase cover over the crankcase Tighten the three right crankcase cover bolts.
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11. COOLING SYSTEM Thermosensor THERMOSENSOR THERMOSENSOR REMOVAL Remove the seat, met-in box and center cover. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor Wire THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up. Temperature(℃ Resistance(Ω) ) 50 80 154 52 100 27 Thermosensor 120 16 Thermometer Thermosensor THERMOSENSOR INSTALLATION Apply 3-BOND No.
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11. COOLING SYSTEM Thermostat Housing Bolt THERMOSTAT THERMOSTAT REMOVAL Remove the seat, met-in box and center cover. Drain the coolant. Disconnect the water hose from the thermostat housing. Remove the mounting bolt and the thermostat housing from the cylinder head. Thermosensor Wire Water Hose Bolts Remove the thermostat from the thermostat housing.
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11. COOLING SYSTEM ＊ • Do not let the thermostat touch the pan as it will give a false reading. • Replace the thermostat if the valve stays open at room temperature. •Test the thermostat after it is opened for about 5 minutes and holds the temperature at 70℃ . Thermostat Housing THERMOSTAT INSTALLATION The installation sequence is the reverse of removal. Fill the cooling system with the specified coolant.