Radiator & Filling

REMOVAL

1.  Drain coolant

2.  Remove radiator assembly

Refer to CHAPTER 3 "ENGINE REMOVAL".

INSPECTION

1. Inspect:
• Radiator fins. Blow out obstructions with compressed air through rear of radiator. Straighten bent fins with a radiator comb.
• Coolant hoses. Replace if cracked or damaged.

2. Measure:

• Valve opening pressure (Radiator cap 1 ) Use the Cooling System Tester (90890-01325).  Replace if out of specification.

Valve Opening Pressure: 78-98kPa(0.8 -1.0 kg/cm, 11.4-14.2 lb/in²)

• Fan motor assembly 1

3. Check valve in the radiator cap for weak spring/defective seating. Replace radiator cap if defective.

INSTALLATION

1.  Install fan motor assembly 1

2.  Tighten bolts.

Fan Motor: 7Nm(0.7m-kg, 5.1ft-lb)

3.  Install radiator assembly

4.  Tighten bolts

Radiator: 7Nm(0.7m-kg, 5.1 ft-lb)

5.  Add coolant

6.  Check cooling system.

Inspection steps:

• Connect the Cooling System Tester (90890-01325)1.
• Apply 98 kPa (1.0 kg/cm², 14 psi) pressure.
• Measure pressure with gauge.

Decrease of pressure indicates leaks in system. Locate and repair as required.

Coolant: Use High-Quality Ethylene Glycol Anti-Freeze Containing Anti-Corrosion Inhibitors for Aluminum Engines.

Coolant and Soft Water Mix Ratio: 50%/50%

Total Amount: 2.40 L (2.11 Imp qt, 2.54 US qt)
Reservoir Tank Capacity: 0.49 L (0.43 Imp qt, 0.52 US qt)
From LOW to FULL Level: 0.14 L (0.12 Imp qt, 0.15USqt)

CAUTION:
Hard water or salt water is harmful to the engine parts. You may use boiled water or distilled water if no soft water is available.

COOLANT FILLING

1. Tighten: • Coolant drain bolts 1, 2 ,3

Drain Bolt: 16 Nm (1.6m-kg, 11 ft-lb)

2. Fill radiator

Coolant filling steps:
• Remove the radiator cap.
• Pour coolant into the radiator to specified level.
• Start the engine (Coolant level decreases).
• Add coolant while the engine is running.
• Stop the engine when coolant level stabilizes.
• Add coolant again to specified level.
• Install the radiator cap.

 

CAUTION:
Always check coolant level, and check for coolant leakage before starting the engine.

3.  Fill the reservoir tank 1

Add coolant until liquid reaches "FULL" level mark 2 .

4.  Install the reservoir tank cap 3

5. Install:
• Radiator cap 1
• Cap retainer 2