Removal
1. Before removing a hose, drain the coolant (see Chapter 1).
2. Use a screwdriver to slacken the larger-bore hose clamps, then slide them back along the hose and clear of the union spigot. The smaller-bore hoses are secured by spring clamps which can be expanded by squeezing their ears together with pliers.
Caution: The radiator unions are fragile. Do not use excessive force when attempting to remove the hoses.
3. If a hose proves stubborn, release it by rotating it on its union before working it off. If all else fails, cut the hose with a sharp knife. Whilst this means replacing the hose, it is preferable to buying a new radiator.
4. The inlet and outlet unions to the cylinders and cylinder heads can be removed by unscrewing their bolt(s) (see illustration). If a union is removed, its O-ring must be replaced with a new one.
9.4. Coolant inlet union (arrowed) - XL600V
Installation
5. Slide the clamps onto the hose and then work the hose on to its union.
If the hose is difficult to push on its union, soften it by hint soaking it in very hot water, or alternatively a little soapy water on the union can be used as a lubricant.
6. Rotate the hose on its unions to settle it in position before sliding the clamps into place and tightening them securely.
7. If an inlet or outlet union to the engine has been removed, install it using a new O-ring, smeared with a dab of grease to hold it in place if necessary. Install the union and tighten the bolt(s) securely.