Category Archives: ANUAL SERVICE M

REMOVAL

REMOVAL

Drain the coolant (page 7-7).

Remove the bolts, water hose joint and O-ring.

Remove the drain bolt and sealing washer. Remove the bolts and water pump cover.

Remove the O-ring and dowel pin.

Loosen the impeller.

Remove the right crankcase cover (page 11-5).

REMOVALRemove the impeller, washer and water pump shaft from the right crankcase cover.

IMPELLER

WASHER

WATER PUMP SHAFT RIGHT CRANKCASE COVER

WATER PUMP SHAFT

Check the water pump shaft for wear or damage.

REMOVAL

WATER PUMP SHAFT BEARING

REMOVAL

Turn the inner race of the water pump shaft bearing with your finger.

The bearing should turn smoothly and quietly.

Also check that the bearing outer race fits tightly in the right crankcase cover.

Replace the water pump shaft bearing if the inner race does not turn smoothly, quietly, or if the outer race fits loosely in the right crankcase cover.

MECHANICAL

REMOVAL

SEAL

Check the mechanical seal for damage or deteriora­tion.

Replace the mechanical seal if necessary (page 7-12).

RADIATOR

REMOVAL/INSTALLATION

RADIATOR GRILLS

Drain the coolant (page 7-7). Remove the fuel tank (page 3-8).

Remove the radiator grills.

Note the direction of the water hose clamp. Be careful not to damage the radiator

SIPHON HOSE

CONNECTING HOSE

Disconnect the following:

— Siphon hose

— Connecting hose

— Upper and lower radiator hoses

RADIATOR HOSES

BOLTS

Remove the upper and lower mounting bolts. Remove the radiator from the frame.

RADIATORBe careful not to Installation is in the reverse order of removal. damage the radiator р. ц system wjt^ t^e recommen(jed coolant and bleed the air (page 7-7).

core.

After installation, check the radiator and radiator hoses for leaks.

RADIATOR RESERVE TANK

REMOVAL/INSTALLATION

SIPHON HOSE ■■ OVERFLOW HOSE

Remove the right and center engine guard (page 3-5).

Remove the reserve tank cap and reserve tank.

Disconnect the radiator siphon and reserve tank overflow hoses from radiator reserve tank.

Drain the reserve tank coolant.

Route the hoses Installation is in the reverse order of removal.

RESERVE TANK

properly (’05 — ’07: page 1-25. After 07: page 1-32).

WATER PUMP

MECHANICAL/OIL SEAL INSPECTION

Check for signs of seal leakage.

If water leaks through the bleed hole, replace the mechanical seal (page 7-12).

If oil leaks through the bleed hole, replace the oil seal (page 7-12).

A small amount of "weeping" from the bleed hole is normal.

REPLACEMENT/AIR BLEEDING

DRAIN BOLT/SEALING WASHER

RESERVE TANK

REPLACEMENT/AIR BLEEDING

Remove the right and center engine guard (page 3-5). Remove the radiator cap.

Drain the coolant from the system by removing the drain bolt and sealing washer on the water pump cover.

Install the drain bolt with a new sealing washer. Tighten the drain bolt securely.

Disconnect the siphon hose from the reserve tank.

Remove the reserve tank cap and reserve tank.

Drain the reserve tank coolant.

Empty the coolant and rinse the inside of the reserve tank with water.

Route the hoses properly (’05 — ’07: page 1-25, After ’07: page 1-32).

Reinstall the reserve tank and connect the radiator siphon hose.

Install the right and center engine guard (page 3-5).

Fill the system with the recommended coolant through the filler opening up to the filler neck.

CAPACITY:

1.21 liter (1.28 US qt, 1.06 Imp qt) at change

Lean the machine approximately 20° to the right and left several times to bleed any air trapped in the cooling system. If the coolant level drops, add more coolant and repeat the air bleeding procedure.

Remove the radiator reserve tank cap and fill the

"UPPER" LEVEL LINE

REPLACEMENT/AIR BLEEDING

reserve tank to the upper level line.

Bleed air from the system as follow:

1. Shift the transmission into neutral. Start the engine and let it idle for 2 — 3 minutes.

2. Snap the throttle three to four times to bleed air from the system.

3. Stop the engine and add coolant up to proper level if necessary. Reinstall the radiator cap.

4. Check the level of coolant in the reserve tank and fill to the "UPPER" level line if it is low.

REPLACEMENT/AIR BLEEDING

SYSTEM TESTING

COOLANT (HYDROMETER TEST)

RADIATOR CAP

Make sure the engine is cool, remove the radiator cap.

Test the coolant specific gravity using a hydrome­ter.

STANDARD COOLANT CONCENTRATION: 1 : 1

COOLANT GRAVITY CHART

I

Coolant temperature °С

°F)

0

(32)

5

(41)

10

(50)

15

(59)

20

(68)

25

(77)

30

(86)

35

(95)

40 45 (104) (113)

50

[(122)

Coolant ratio%

5

1.009

1.009

1.008

1.008

1.007

1.006

1.005

1.003

1.001 0.999

0.997

10

1.018

1.017

1.017

1.016

1.015

1.014

1.013

1.011

1.009

1.007

1.005

15

1.028

1.027

1.026

1.025

1.024

1.022

1.020

1.018

1.016

1.014

1.012

20

1.036

1.035

1.034

1.033

1.031

1.029

1.027

1.025

1.023

1.021

1.019

25

1.045

1.044

1.043

1.042

1.040

1.038

1.036

1.034

1.031

1.028

1.025

30

1 053

1.052

1.051

П.047

1.046

1.045

1.043

1.041

1.038

1.035

1.032

35

1.063

1.062

1.060

1.058

1.056

1.054

1.052

1.049

1.046

1.043

1.040

40

1.072

1.070

1.068

1.066

1.064

1.062

1.059

1.056

1.053

1.050

1.047

45

1.080

1.078

1.076

1.074

1.072

1.069

1.066

1.063

1.060

1.057

1.054

50

1.086

1.084

1.082

1.080

1.077

1.074

1.071

1.068

1.065

1.062

1.059

55

1.095

1.093

1.091

1.088

1.085

1.082

1.079

1.076

1.073

1.070

1.067

60

1.100

1.098 1.095

1.092

1.089

1.086

1.083

О

00

о

«—

1.077

1.074

1.071

HYDROMETER

Look for contamination and replace the coolant if necessary.

RADIATOR CAP/SYSTEM PRESSURE INSPECTION

SYSTEM TESTING

RADIATOR CAP TESTER

Remove the radiator cap.

Wet, he sealing Install the radiator cap on the tester. surface with water. pressure test the radjator cap

Replace the radiator cap if it does not hold pressure, or if the relief pressure is too high or too low.

It must hold the specified pressure for at least 6 sec­onds.

RADIATOR CAP RELIEF PRESSURE:

SYSTEM TESTING

RADIATOR CAP TESTER

108 — 137 kPa (1.1 — 1.4 kgf/cm2,16 — 20 psi)

Pressure test the radiator, engine and hoses, and check for leaks.

NOTICE

Excessive pressure can damage the cooling system components. Do not exceed 137 kPa (1.4 kgf/cm2, 20 psi).

Repair or replace components if the system will not hold the specified pressure for at least 6 seconds.

After checking the pressure, install the radiator cap securely.

COOLANT REPLACEMENT

PREPARATION

SYSTEM TESTING

• If any coolant gets in your eyes, rinse them with water and consult a doctor immediately.

RECOMMENDED

ANTIFREEZE

• If any coolant in swallowed, induce vomiting, gargle and consult a physician immediately.

• If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water.

(ETHYLENE GLYCOLBASE SOLUTION)

LOWMINERAL OR DISTILLED WATER

SYSTEM TESTING

• The effectiveness of coolant decreases with the accumulation of rust or if there is a change in the mixing proportion during usage. Therefore, for best performance, change the coolant regularly as specified in the maintenance schedule.

• Mix only distilled, low mineral water with the antifreeze.

COOLANT

RECOMMENDED ANTIFREEZE:

Pro Honda HP coolant or an equivalent high qual­ity ethylene glycol antifreeze containing silicate- free corrosion inhibitors

RECOMMENDED MIXTURE:

1 :1 (distilled water and recommended antifreeze)