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.
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.
3. Drain the coolant (see page 11-5).
4. Disconnect the top hose and expansion tank hose at the radiator.
5. Disconnect the bottom hose from the radiator.
1. Top hose; 2. Expansion tank hose; 3. Bottom hose; 4. Ciips
6. Release the radiator lower mounting.
1. Radiator lower mount fixing
7. Disconnect the cooling fan connection, located above the camshaft cover.
8. Detach the clutch cable from the radiator clip.
9. Release the fixing securing the radiator to the frame., and release the radiator grommet from the right hand mounting pin.
1. Radiator to frame fixing; 2. Radiator grommet; 3. Clutch cable clip; 4. Radiator removal direction
10. Remove the radiator.
Inspection
1. Check the radiator for stone damage.
2. Check the radiator core for damage to the fins or obstructions to air flow.
3. Repair any damage and clear all obstructions.
Caution: To avoid overheating and consequent engine damage, replace the radiator if the cores are blocked or if the fins are badly deformed or broken.
4. Check that the fan spins freely and without tight spots.
5. Check the fan blades for signs of heat distortion.
Installation
1. Align the radiator grommet to the frame stud. Fit the upper mounting bolt and tighten the bolt to 6 Nm.
2. Align the radiator lower mounting to the bracket on the engine. Fit and tighten the lower mounting bolt to 6 Nm.
3. Reconnect the cooling fan.
4. Reconnect the expansion tank, and top and bottom hoses. Tighten the hose clips to 2 Nm, ensuring they are repositioned as noted prior to disassembly.
5. Refill the cooling system (see page 11-5).
6. Reconnect the battery, positive (red) lead first.
7. Refit the rider's seat (see page 16-13).