| PART NO. | SPECIALTY TOOL |
| HD-29545-6 | Coolant fluorescent leak detection dye |
| HD-35457 | Black light leak detector |
Note. If the coolant overflow bottle is empty when the engine is cold, it is possible that air has been drawn into the coolant system. The system must be purged of any trapped air and refilled with coolant.
1. Before troubleshooting cooling system be sure engine coolant level is at COLD FULL mark on overflow bottle when the motorcycle is on the jiffy stand.
Warning! Do not remove the pressure cap when the engine is hot. The cooling system is under pressure and hot coolant and steam may escape causing severe burns. Allow engine to cool before servicing the cooling system.
2. Using a cloth over pressure cap, turn cap 1/4 turn counterclockwise (CCW) to safety stop. Let pressure escape. Press down and turn cap to pass over safety stops of filler neck and remove.
3. If filler neck is full of coolant, remove an amount of coolant equal to the amount of dye.
4. See Figure 6-6. Pour COOLANT FLUORESCENT LEAK DETECTION DYE (HD-29545-6) into filler neck.
Figure 6-6. Pouring dye into filler neck
5. Replace pressure cap and run engine for 10 minutes.
6. Use BLACK LIGHT LEAK DETECTOR (HD-35457) to illuminate entire cooling system. A yellow fluorescence at any spot indicates a leak.
7. Remove oil dipstick and inspect engine oil for yellow dye.
Note. Dye in the oil may indicate a damaged engine head gasket. Draining and replacing coolant contaminated oil will be necessary as part of engine service.