Removal
Note: Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly.
1. Remove the rider's seat (see page 16-13).
2. Disconnect the battery, negative (black) lead first.
3: Drain the coolant (see page 11-5).
4. Remove the fuel tank (see page 10-91).
5. Remove the airbox (see page 10-98).
6. Remove the throttle bodies (see page 10-107).
Warning: Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage.
7. Detach the top hose from the thermostat elbow.
8. Release the fixings securing the thermostat elbow to the cylinder head.
9. Remove the thermostat housing.
1. Thermostat housing; 2. Fixings
10. Remove the thermostat from the cylinder head. Discard the seal.
1. Thermostat; 2. Bleed valve
Inspection
1. Inspect the thermostat at room temperature. If the valve is open, the thermostat must be replaced.
2. To check the valve opening temperature, suspend the thermostat in a container of water and raise the temperature of the water until the thermostat opens. The thermostat should start to open at 71±5°C.
3. If the temperature at which thermostat opening takes place is incorrect, replace the thermostat.
Installation
1. Fit a new seal to the thermostat.
2. Locate the thermostat into the cylinder head. Ensure the bleed valve is uppermost as shown below.
1. Thermostat; 2. Bleed valve
3. Refit the thermostat housing and tighten the fixings to 9 Nm.
4. Reconnect the top hose and tighten the clip. Tighten to 2 Nm.
5. Refit the throttle bodies (see page 10-107).
6. Refit the airbox (see page 10-98).
7. Refit the fuel tank (see page 10-91).
8. Reconnect the battery positive (red) lead first.
9. Refit the rider's seat (see page 16-13).
10. Refill the cooling system (see page 11-5).