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. Position the motorcycle on level ground on the sidestand.
2. Remove the rider's seat (see page 16-13).
3. Disconnect the battery, negative (black) lead first.
4. Drain the coolant (see page 11-5).
5. Drain the engine oil (see page 8-7).
Warning: The oil may be hot to the touch. Contact with hot engine oil may cause skin to be scalded or burnt.
Warning: Prolonged or repeated contact with engine oil can lead to skin dryness, irritation and dermatitis. In addition used engine oil contains potentially harmful contaminants which can cause cancer. Wear suitable clothing and avoid skin contact.
6. Disconnect the coolant hoses from the heat exchanger.
7. Remove the centre bolt from the heat exchanger and withdraw it from the crankcase. Remove and discard the heat exchanger О-ring and the centre bolt sealing washer.
1. Heat exchanger; 2. Centre bolt; 3. Coolant hose clips
Inspection
1. Check the heat exchanger body for corrosion and/or damage.
Installation
1. Fit a new О-ring to the heat exchanger, and a new sealing washer to the centre bolt.
1. Centre bolt; 2. Sealing washer; 3. Heat exchanger; 4. О-ring
Note: To ensure correct positioning, ensure that the tab on the heat exchanger locates in the boss provided in the crankcase.
Caution: Do not rely on the tab to hold the heat exchanger in position while tightening the centre bolt. The tab will bend and will not prevent the heat exchanger from turning. Instead, firmly hold the heat exchanger in position by hand.
1. Heat exchanger tab; 2. Crankcase boss
2. Fit the heat exchanger to the crankcase and tighten the centre bolt to 59 Nm.
3. Fit the coolant hoses to the heat exchanger and tighten the coolant hose clips.
1. Heat exchanger; 2. Centre bolt; 3. Coolant hose clips
4. Refill the cooling system (see page 11-5).
5. Refill the engine with oil (see page 8-7).
6. Reconnect the battery, positive (red) lead first.
7. Start the engine and check for oil leaks. Once a leak check has been made, stop the engine and allow to stand for 3 minutes.
8. Adjust the engine oil level (see page 8-6).
9. Refit the rider's seat (see page 16-13).