COOLING SYSTEM

1. Removing cooling system .............10-2

1.1 Removing cooling fan,
fan pulley and V-belt .............................. 10-2
1.2 Removing thermostat............................. 10-3
1.3 Removing water pump ........................... 10-4

2. Disassembling, inspecting and

reassembling cooling system ........10-5
2.1 Disassembling and inspecting
thermostat .............................................. 10-5
2.2 Inspecting thermostat............................. 10-6
2.3 Disassembling water pump.................... 10-7
2.4 Inspecting water pump........................... 10-7

3. Installing cooling system ...............10-8

3.1 Installing water pump ............................. 10-8
3.2 Installing thermostat............................... 10-9
3.3 Installing cooling fan, fan pulley and
V-belt.................................................... 10-10

10-1
COOLING SYSTEM

1. Removing cooling system

1.1 Removing cooling fan, fan pulley and V-belt

Crack, extension,
wear, damage
4

Crack, deformation, damage

Removing cooling fan, fan pulley and V-belt

Removing sequence

1 Plate 3 V-belt
2 Cooling fan 4 Water pump pulley

10-2
 COOLING SYSTEM

1.2 Removing thermostat

2 3

Replace

Crack, water leakage, damage

Crack, deterioration, damage

1

Removing thermostat
Removing sequence

1 Hose 2 Thermostat assembly 3 Gasket

10-3
COOLING SYSTEM

1.3 Removing water pump

Replace 2

Replace
4

Crack, deformation, damage

Removing water pump

Removing sequence

1 Water pump assembly 2 Gasket 3 Water pump spacer 4 Gasket

10-4
 COOLING SYSTEM

2. Disassembling, inspecting and reassembling cooling system

2.1 Disassembling and inspecting thermostat

Replace
2

Disassembling and inspecting thermostat

Disassembling sequence

1 Cover assembly 3 Gasket 5 Thermostat case

2 Gasket 4 Thermostat

10-5
COOLING SYSTEM

2.2 Inspecting thermostat

9
CAUTION

Valve lift mm [in.]

[0.35]
Be careful of burns or fires when measuring tempera-
tures, especially if it involves high-temperatures and 0
76.5 °C 90°C
open flame. [170°F] [194°F]
Temperature
To test thermostat operation, immerse the thermostat in a
container filled with water. Heat the water, while measuring
the water temperature. Record the temperature at the
conditions shown in the table below. If the temperatures are
not within the standard range, replace the thermostat.
Note: (a) Stir the water in the container with a stick to
Removing thermostat
ensure uniform temperature distribution.
(b) Before installing the thermostat, be sure to check
the valve opening temperature stamped on the
thermostat valve side face.

Item Standard
76.5 ± 1.5°C
Temperature at which valve starts opening
[170 ± 2.7°F]
Temperature at which valve lift becomes 90 ± 1.5°C
9 mm [0.35 in.] or more. [194 ± 2.7°F]

10-6
 COOLING SYSTEM

2.3 Disassembling water pump

Crack, water leakage,

deformation

Replace
Crack, water leakage, damage,
impeller and shaft rotation
3

Disassembling water pump

Disassembling sequence

1 Water pump cover 2 Gasket 3 Water pump

2.4 Inspecting water pump

Check to make sure that the impeller and water pump shaft
rotate smoothly without noises and irregularities. If faulty,
replace the assembly.

10-7
COOLING SYSTEM

3. Installing cooling system

3.1 Installing water pump

Water pump and

water pump cover fixing bolts(× 3)
9.8 ± 1 N·m
{1 ± 0.1 kgf·m}
[7.2 ± 0.7 lbf·ft]

Crack, deformation, Replace

damage

Replace

31.9 ± 2.4 N·m

{3.3 ± 0.2 kgf·m}
[23.5 ± 1.8 lbf·ft]
Water pump and crankcase fixing bolts(× 5)
18.2 ± 3.4 N·m
{1.9 ± 0.3 kgf·m}
[13.4 ± 2.5 lbf·ft]

Installing water pump

10-8
 COOLING SYSTEM

3.2 Installing thermostat

18.5 ± 1.5 N·m

Replace
{1.9 ± 0.1 kgf·m}
[13.6 ± 1.1 lbf·ft]

Crack, water leakage, damage

Crack, deterioration,
damage

Installing thermostat

10-9
COOLING SYSTEM

3.3 Installing cooling fan, fan pulley and V-belt

Crack, extension,
wear, damage

Crack, deformation, damage

Installing cooling fan, fan pulley and V-belt

CAUTION
Inspect and adjust the V-belt every 200 hours of oper-
ation.
Depending on the operating condition, the inspecting
and adjusting interval may be shortened.

10-10