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11. COOLING SYSTEM

11-0

SUPER 9 50

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COOLING SYSTEM

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SERVICE INFORMATION -------------------------------------------- 11- 1

TROUBLESHOOTING ------------------------------------------------- 11- 1

RADIATOR -------------------------------------------------------------- 11- 3

WATER PUMP ---------------------------------------------------------- 11- 6

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

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

Summary of content (15 pages)

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11. COOLING SYSTEM SUPER 9 50 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.
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11. COOLING SYSTEM SUPER 9 50 SPECIFICATIONS Begins to open Full-open Valve lift Thermostat temperature 80±2℃ 90℃ 3.5_ 4.5mm 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 1.093 1.098 1.008 1.017 1.026 1.034 1.
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11. COOLING SYSTEM RADIATOR SUPER 9 50 Front Upper Cover RADIATOR INSPECTION Remove the front upper cover. (!2-3) Remove the front lower cover. (!2-3) Front Lower Cover 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.
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11. COOLING SYSTEM Loosen the hose band and disconnect the upper hose from the radiator. SUPER 9 50 Upper Hose Radiator Loosen the hose band and disconnect the lower hose from the radiator. Lower Hose Remove the two bolts and the radiator.
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11. COOLING SYSTEM SUPER 9 50 RADIATOR BRACKET REMOVAL/ INSTALLATION Remove the two nuts to remove the radiator bracket. The installation sequence is the reverse of removal. Nuts Radiator Bracket RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts. Radiator Bolts Connect the upper and lower hoses and secure them with hose bands.
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11. COOLING SYSTEM SUPER 9 50 Upper Hose Reinstall the upper and lower hoses, make sure the bands are secured. Reserve Tank . Fill the reserve tank with coolant. (!3-10) Check for coolant leaks. Install the front upper and lower cover. Air Duct Lower Hose Reserve Tank 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 SUPER 9 50 WATER PUMP/IMPELLER REMOVAL Remove the engine from the frame. (!5-2) Remove the three bolts and the water pump cover, gasket and two dowel pins. Bolts Water Pump Cover Remove the water pump impeller. ＊ The impeller has left hand threads.
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11. COOLING SYSTEM Inspect the mechanical (water) seal and seal washer for wear or damage. SUPER 9 50 Mechanical Seal Seal Washer (Porcelain) ＊ The mechanical seal and seal washer must be replace as a set. Impeller WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove the two timing cap bolts and the timing cap. Remove the three bolts attaching the water pump assembly. Remove the water pump assembly and dowel pins.
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11. COOLING SYSTEM WATER PUMP BEARING/ MECHANICAL S EAL REMOVAL Remove the water pump shaft inside bearing. SUPER 9 50 Water Pump Assembly Inside Bearing Water Pump Assembly Drive the mechanical seal out of the water pump assembly from the outer. Mechanical Seal (Water Seal) Remove the water pump shaft outer bearing.
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. COOLING SYSTEM WATER PUMP BEARING/ MECHANICAL S EAL INS TALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside. Drive a new water pump shaft inside bearing into the water pump assembly from the inside. SUPER 9 50 Water Pump Assembly Outer Bearing Inside Bearing 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 SUPER 9 50 Install the dowel pins and then install the water pump assembly to the right crankcase. Tighten the three bolts to secure the water pump assembly. Install the two timing cap bolts and the timing cap. Water Pump Assembly ＊ When installing the water pump assembly, aligning the tab on the water pump shaft with the groove on the A.C. generator nut. WATER PUMP/IMPELLER INSTALLATION When the mechanical seal is replaced, a new seal washer must be installed to the impeller.
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11. COOLING SYSTEM SUPER 9 50 Thermosensor THERMOSENSOR THERMOSENSOR REMOVAL Remove the seat, met-in box and frame body 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.
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11. COOLING SYSTEM SUPER 9 50 Thermostat Housing THERMOSTAT Screws THERMOSTAT REMOVAL Remove the seat, met-in box and frame body cover. Drain the coolant. Disconnect the water hose from the thermostat housing. Water Hose Remove the two screws and separate the thermostat housing cover . Remove the thermostat from the thermostat housing. THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation.
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11. COOLING SYSTEM SUPER 9 50 THERMOSTAT INSTALLATION The installation sequence is the reverse of removal. Fill the cooling system with the specified coolant.