COOLING SYSTEM

Care to be taken while working on Water cooled engine Coolant refilling & Air bleeding Cooling system parts

Engine oil drain • Remove radiator cap.

• Engine should be in warm condition • Remove bleeder screw.
• Engine oil specifications - 20W50 • Pour in coolant until it emerges without bubbles at
the vent hole, then mount and tighten the bleeder RADIATOR RELAY BLEEDER SCREW
• Drain & Refill quantity - 1200 ml screw immediately.
• Engine overhaul quantity - 1400 ml • Fill the radiator completely with coolant. Mount the THERMOSTAT FAN MOTOR

Important : Always use clean tray, measuring jar & funnel for oil radiator cap.
draining & refilling. • Rest the vehicle on the side stand.
• When the engine is cool, check the coolant level in
Coolant level inspection & top-up during periodic service the radiator and, if necessary, add coolant. COOLANT
TEMPERATURE
RADIATOR
SENSOR
• Remove the cap of the expansion tank (reservoir)
• Engine should be in cold condition.
and add coolant until the coolant level is up the
• Coolant level should be upto max mark in expansion tank. MAX mark.
• If level is found less then top-up with coolant upto max mark. • Mount the cap of the expansion tank.
EXPANSION
• Recommended brand - COOLANT TANK
PUMP RADIATOR CAP
Radicool (Castrol), Motocool expert (Motul) Precaution for avoiding coolant & oil mixing RADIATOR
HOSE
AND CLAMP
• Always replace cylinder head gasket by new one.
Coolant draining
• Always replace cylinder block gasket by new one.
During motorcycle operation, the coolant gets very hot & is under • Always replace radiator pump oil seals whenever • Radiator : To cool the coolant as it • Radiator Clamps : For firm fitting of
pressure. Do not remove the radiator cap, radiator hoses or other crankcase splitting is done. flows through the fins. radiator hose.
cooling system components when the engine is hot. Allow the engine • Bleeder Screw : For removing air • Expansion Tank : This is an additional
and cooling system to cool down. from coolant. tank for supply of coolant to radiator.
• Stand the motorcycle upright. • Radiator Cap : Suction & delivery of • Coolant Temperature Sensor : Senses
coolant in expansion tank as per coolant temperature.
• Place a suitable container under the engine. temperature & pressure of coolant. • Radiator Relay : For controlling fan
• Remove coolant drain screw. • Thermostat : To regulate the flow of motor operation.
coolant for quick warm up and cooling • Fan Motor : For cooling of radiator
• Take off the radiator cap.
of engine. coolant.
• Completely drain the coolant from radiator & expansion tank by • Radiator Hose : For carrying coolant • Coolant Pump : For circulation of
tilting the vehicle on RH side. from radiator to pump and engine to coolant in the system.
• Mount screw with a new sealing ring and tighten it. radiator.

CIN L65993PN2007PLC130076
 COOLANT FLOW & DIAGNOSIS

Faults Possible Cause Action

Pump

Pump

Cylinder block passage

(Through Clutch side crankcase)

Cylinder Head

Thermostat valve

Coolant Temp Coolant Temp

Less than 820C more than 820C
Pump through Bypass pipe Radiator LHS Top

Radiator RHS Bottom

Thermostat
A bad shaft seal will allow coolant to dribble
Pump out of the vent hole just under water pump shaft.
Defective gasket or ‘O’ ring sealing pump to
engine front cover can also leak coolant.
Always replace cylinder head or block gasket
whenever these parts opening is carried out.
Pump