dummytext

8. COOLING SYSTEM

SERVICE INFORMATION························ 8-2 THERMOSTAT ······································ 8-6

8
TROUBLESHOOTING ···························· 8-2 RADIATOR/COOLING FAN ····················· 8-7

SYSTEM FLOW PATTERN······················ 8-3 RADIATOR RESERVE TANK··················· 8-9

SYSTEM TESTING································· 8-4 WATER PUMP ···································· 8-10

COOLANT REPLACEMENT ···················· 8-5 WATER HOSE JOINT··························· 8-11

8-1
 dummyhead

COOLING SYSTEM
SERVICE INFORMATION
COOLING SYSTEM

GENERAL

Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you.
Always let the engine and radiator cool down before removing the radiator cap.

Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages.
Using tap water may cause engine damage.
• The coolant should be inspected and replaced properly by following the maintenance schedule (page 3-3).
• DO NOT use non-ethylene glycol coolant, tap water, nor mineral water when adding or replacing the coolant.
Use of improper coolant may cause damage, such as corrosion in the engine, blockage of the cooling passage or the radiator
and premature wear of the water pump seal.
• Add cooling system at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
• All cooling system services can be done with the engine in the frame.
• Avoid spilling coolant on painted surfaces.
• After servicing the system, check for leaks with a cooling system tester.
• For high coolant temperature indicator (page 21-11).
• For fan control relay inspection (page 21-21).

TROUBLESHOOTING
Engine temperature too high
• Faulty high coolant temperature indicator or ECT sensor or ECM (page
21-11)
• Thermostat stuck closed
• Faulty radiator cap
• Insufficient coolant
• Passage blocked in radiator, hoses or water jacket
• Air in system
• Faulty cooling fan motor
• Faulty fan control relay (page 21-21)
• Faulty water pump
Engine temperature too low
• Faulty high coolant temperature indicator or ECT sensor or ECM (page
21-11)
• Thermostat stuck open
• Faulty fan control relay
Coolant leak
• Faulty water pump mechanical seal
• Deteriorated O-rings
• Faulty radiator cap
• Damaged or deteriorated cylinder head gasket
• Loose hose connection or clamp
• Damaged or deteriorated hose
• Damaged radiator

8-2
dummyhead

COOLING SYSTEM
SYSTEM FLOW PATTERN

RADIATOR CAP
UPPER RADIATOR HOSE

RADIATOR

SIPHON HOSE

WATER PUMP-TO-
CYLINDER BLOCK HOSE

THERMOSTAT

LOWER RADIATOR HOSE OVERFLOW HOSE

WATER PUMP RADIATOR

BYPASS HOSE
RESERVE TANK

8-3
 dummyhead

COOLING SYSTEM
SYSTEM TESTING
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Remove the screw [1] and radiator cap [2]. [2]

[1]

Wet the sealing surfaces of the cap [1], then install the
[2]
cap onto the tester [2].
Pressurize the radiator cap using the tester.
Replace the radiator cap if it does not hold pressure, or
if relief pressure is too high or too low.
The cap must hold the specified pressure for at least 6
seconds.
RADIATOR CAP RELIEF PRESSURE:
108 – 137 kPa (1.1 – 1.4 kgf/cm2, 16 – 20 psi)
Connect the tester to the radiator.
Pressurize the radiator, engine and hoses using the [1]
tester, and check for leaks.

Excessive pressure can damage the cooling system

components. Do not exceed 137 kPa (20 psi).
Repair or replace components if the system will not hold
the specified pressure for at least 6 seconds.

8-4
dummyhead

COOLING SYSTEM
COOLANT REPLACEMENT
REPLACEMENT/AIR BLEEDING

• When filling the system or reserve tank with coolant,

or checking the coolant level, place the motorcycle [4]
in an upright position on a flat, level surface.
Lift the fuel tank and support it (page 3-4).
Remove the rider left footpeg bracket (page 18-10).
Remove the water pump drain bolt [1] and sealing
washer [2].
Remove the screw [3] and radiator cap [4] and drain the
coolant.
Remove the cylinder drain bolt [5], sealing washer [6]
and drain the coolant from the cylinder.
Reinstall the drain bolts with new sealing washers. [1]/[2] [3]

Tighten the drain bolts to the specified torque.

TORQUE:
Water pump drain bolt:
13 N·m (1.3 kgf·m, 10 lbf·ft)
Remove the radiator reserve tank (page 8-9).
Empty the coolant and rinse the inside of the reserve
tank with water.
Install the radiator reserve tank (page 8-9).
Install the following:
– fuel tank (page 3-4)
– left rider footpeg bracket (page 18-10) [5]/[6]

Fill the system with the recommended coolant through

[1] [2]
the filler opening up to filler neck [1].
RECOMMENDED ANTIFREEZE:
Pro Honda HP Coolant or an equivalent high
quality ethylene glycol antifreeze containing
silicate-free corrosion inhibitors

STANDARD COOLANT CONCENTRATION:

1:1 mixture with distilled water
Bleed air from the system as follow:
1. Shift the transmission into neutral.
Start the engine and let it idle for 2 – 3 minutes. [3]
2. Snap the throttle 3 – 4 times to bleed air from the
system.
3. Stop the engine and add coolant up to the filler neck
if necessary.
4. Install the radiator cap [2] and screw [3].
Fill the reserve tank with the recommended coolant
(page 3-12).

8-5
 dummyhead

COOLING SYSTEM
THERMOSTAT
REMOVAL/INSTALLATION
Drain the coolant (page 8-5).
[1]
Remove the socket bolts [1], heat guard [2] and washer
[3].

[3] [2]

Remove the socket bolts [1] and thermostat cover [2].

[2]

[1]

Remove the thermostat [1] from the cylinder head.

Align [2]
Installation is in the reverse order of removal.
TORQUE:
Thermostat cover socket bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

• Install the thermostat with the air bleed hole [2]

facing up, aligning the body ribs with the grooves of
the cylinder head.
Fill and bleed the cooling system (page 8-5).

[1]

8-6
dummyhead

COOLING SYSTEM
INSPECTION
Visually inspect the thermostat [1] for damage.
[2]
Replace the thermostat if the valve stays open at room
temperature.
Check the seal ring [2] for damage and replace if
necessary.

[1]

Wear insulated Heat the water with an electric heating element to

[1]
gloves and operating temperature for 5 minutes.
adequate eye
Suspend the thermostat [2] in heated water to check its
protection. Keep
operation.
flammable
materials away THERMOSTAT BEGIN TO OPEN:
from the electric 81 – 84°C (178 – 183°F)
heating element.
Do not let the VALVE LIFT:
thermostat or 8 mm (0.3 in) minimum at 95°C (203°F)
thermometer [1]
touch the pan, or Replace the thermostat if it responds at temperatures
you will get false other than those specified.
reading.
[2]

RADIATOR/COOLING FAN
REMOVAL/INSTALLATION
Drain the coolant (page 8-5).
[1]
Remove the ignition switch stay (page 21-14).
Disconnect the fan motor 2P (Black) connector [1] and
remove it from the stay.
Remove the wire band clip [2] from the fan motor
shroud.

[2]

8-7
 dummyhead

COOLING SYSTEM
Release the hose clip [1] and disconnect lower radiator
hose [2].
Remove the left side radiator mounting socket bolt [3]. [3]

[1]
[2]

Disconnect the siphon hose [1].

[1]
Remove the right side radiator mounting socket bolt [2].

[2]

Be careful not to Release the hose clip [1] and disconnect upper radiator
damage the hose [2].
radiator fins. [3]
Release the radiator grommets [3] from the frame
bosses by moving the radiator to the right to remove the
radiator.
Installation is in the reverse order of removal.
Fill and bleed the cooling system (page 8-5).

[1]
[2]

8-8
dummyhead

COOLING SYSTEM
DISASSEMBLY/ASSEMBLY
Disassemble and assemble the radiator as shown in the following illustration.

RADIATOR COVER
RADIATOR CAP
COOLING FAN NUT
1.1 N·m (0.1 kgf·m, 0.8 lbf·ft)

Align

SCREW

COOLING FAN
RADIATOR
FAN MOTOR

FAN MOTOR SHROUD

FAN MOTOR SCREW

FAN MOTOR SHROUD BOLT 2.8 N·m (0.3 kgf·m, 2.1 lbf·ft)
8.5 N·m (0.9 kgf·m, 6.3 lbf·ft)

RADIATOR RESERVE TANK

REMOVAL/INSTALLATION
Remove the following:
[1]
– tank under tray (page 2-8) [8]
– air cleaner housing (page 7-11) [4]
– swingarm (page 17-8) [7]
Remove the socket bolt [1], then release the two
bosses [2] of the reserve tank [3] from the frame.
Disconnect the overflow hose [4] from the reserve tank.
Disconnect the siphon hose [5] and release it from the [6]
[9]
guide [6].
Release the AC generator/ CKP sensor wire [7] and
sidestand switch wire [8] from the guide [9].
[3] [5]
Drain the coolant to remove the radiator reserve tank.
Installation is in the reverse order of removal. [3]
[2]
• Install the reserve tank by aligning the bosses of the
reserve tank with the holes [8] of the frame.
Fill the reserve tank with the recommended coolant
(page 3-12).

[8]

8-9
 dummyhead

COOLING SYSTEM
WATER PUMP
MECHANICAL SEAL INSPECTION
Check the bleed hole [1] of the water pump for signs of
coolant leakage.
• A small amount of coolant weeping from the bleed
hole is normal.
• Make sure that there are no continuous coolant
leakage from the bleed hole while operating the
engine.
Replace the water pump as an assembly if necessary.

[1]

REMOVAL/INSTALLATION

• Place a clean oil pan under the engine because

[4] [3]
engine oil will flow out when removing the water
pump body. Add the recommended engine oil to the
specified level after installation (page 3-10).
Drain the coolant (page 8-5).
Remove the drive sprocket cover (page 2-7).
[1]
Support the motorcycle in an upright position on a level
surface.
Release the hose clips [1] and disconnect the following
from the water pump:
– lower radiator hose [2]
– bypass hose [3] [2]
– water pump-to-cylinder block hose [4]
Remove the following:
[1]
– cover socket bolt [1]
– three mounting socket bolts [2]
– water pump cover [3]

[2] [3]

Remove the cover O-ring [1] from the water pump body
[1]
[2].
Remove the water pump body from the crankcase.

[2]

8-10
dummyhead

COOLING SYSTEM
Remove the water pump body O-ring [1].
Align
Installation is in the reverse order of removal.
TORQUE:
Water pump mounting socket bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)
Water pump cover socket bolt:
13 N·m (1.3 kgf·m, 10 lbf·ft)

• Do not disassemble the water pump body.

• Replace the O-rings with new ones.
• Apply engine oil to the water pump body O-ring.
• Do not apply engine oil to the cover O-ring. [1]
• Align the water pump shaft groove with the oil pump
shaft end by turning the water pump impeller.
Check the oil level (page 3-10).
Fill and bleed the cooling system (page 8-5).

WATER HOSE JOINT

REMOVAL/INSTALLATION
Drain the coolant (page 8-5).
[3] [1] [5]
Remove the throttle body/air cleaner housing assembly
(page 7-11).
Release the hose clip [1] and disconnect the water
pump-to-cylinder block hose [2].
Remove the nuts [3], water hose joint [4] and O-ring [5].
Installation is in the reverse order of removal.

• Replace the O-ring with a new one.

Fill and bleed the cooling system (page 8-5).
[2] [4]

STUD BOLT REPLACEMENT

Remove the water hose joint (page 8-11).
Thread two nuts onto the stud and tighten them
together, and use a wrench on them to turn the stud bolt
out.
Apply locking agent to new stud bolt threads (page 1-
18).
Install the stud bolts into the cylinder block as shown.
After installing the stud bolts, check that the length from
the bolt head to the cylinder block surface is within
specification.
SPECIFIED LENGTH: 15.0 – 16.0 mm (0.59 – 0.63 in) 15.0 – 16.0 mm
(0.59 – 0.63 in)
Install the water hose joint (page 8-11).

8-11
dummyhead

MEMO