3e1 Chapter 3 Cooling system Contents Coolant noses - removal and instalation oat sytem cating Mting and fing ‘see Chapter 1 Coolant iovel chook... s88Daly tori) as General information = 1 Geolant reservoir ~rernoval and installation... Pressure cap - check 2 Coolant temperature gauge and sensor ~ enacx and Radiator ~ removal and instabation ..... 7 replacement . + 8 Thermostat and thermostat housing ~ removal Ccolng fen and cooling fan switch check and replacement 4 check and insiaation 8 Goolng sysiem checks... ‘see Chapter 1 Water pump check, removel and installalien aioe Degrees of difficulty Easy, suitable for Fairty easy, suitable novice with lete & for beginne: with expenence | semeerperonce Specifications ote: Where applicable, models are identified by their production code letter ~ refer to ‘Identification numbers’ at the front of this ‘manual for details. Coolant Nucure type and capacity... 50% distiled water, 50% corrosion ichibted ethylene glyco anti= freeze Pressure cap Cap valve opening prossiva eee 16 to20 pei (1.1 to 1.4 Bat) Fan switch Goolna fen cu-in temperature ae 9810 102°6 Coal fen cu-out ernperatre rai? ss toe7c Coolant temperature sensor Feitance @s0c : 153 t0.179 ohms e800 |... ote a SETI 471087 ohme @ 20 See 44018 ohms Thermostat ‘fering temperature ; cose B0to BAC Bes eid Yoscregapstien ayes LT a mm fin) @ 95°6 Torque settings eating tan swrten 18Nm ‘Coan flor neck-t-theemoctat Reusing bots 12Nm (cola temperature sender - nm Radiator mounting ott. 12Nm Fesoncit tank mounting bolt t2Nm Themosiat housing cover bolis 12Nm at pump gain Bor ae fe a2Nm Water pump body-to-ranicoaga bots 2.0. 2.12 2 gNm Woter pump cover bolts .....cecesssssvevese yeNm3¢2 Cooling system 1 General information ‘The cooling system uses a water/antineeze coolant to camy away excess energy in the form of heat. The cylinders are surrcunded by 1 water jacket from wich the heates ooclant is circulated by therme-syphonic ection in Conjunction with a water pimp, driven dy the ‘il pump. The hot coolant passes upwards to the thermostat and through to the radiator. The coolant then flows across the radiator core, where itis cooled by the passing air, to ‘ne wator purnp and back to the engine wnere the cycle is repeated. ‘A thermostat is fttad in the system to prevent the coolant flowing through the Fadiator when the engine is cold, therefore ‘accelerating the speed at whien the engine feaches normal operating temperature. A coolant temperature sender meunted in the thermostat housing transmits to the temperature gauge on the instrument panel, A thermostatically-controlled cooling fan is fitted behind the radiator to aid ccoling in extrome concstions, ‘The complete cocling system is partially sealed and pressurised, the pressure being ‘conivolid by a spring-loaded valve containad in the spring-loaded pressure cap. By pressuring the coolant the bolling poirt 1s raised, preventing premature boiling in ‘adverse conditions. The averlow pipe from. the system is connected to a reservorr nto, Which excess coolant is expelled under prosaure. Tho discharoed coolant ‘automaticaly reiuins to tie radiator when tha ‘engine coo's Coolant is routed from a union at the basic of the cylinder head to the carturetiors to prevent icing In extreme conaitions and 13 Fetured via ahose to the water pump, Warning: Do not remove the ‘bressure cap from the filer neck ‘when the engine rs hot. Scalding hot coolant and steam may be blown out under pressure, which could ‘cause serious injury. When the engine has 00led, plac a thick rag, like a towel, over the pressure cap; slowly rotate the cap anti-clockwise to the first stop. This procedure allows any residual pressure to escape. When the steam has stopped escaping, press down on the cap while turing it anti-clockwise and remove it. Warning: Do not allow antifreeze to come in contact with your skin or painted surfaces of the matoreyole. Rinse off eny ‘Spills immediately with plenty of water. Antifreeze is highly toxie if ingested. Never leave antifroozo lying around in an open container or in puddles on the floor: children and pets are attracted by Its sweet ‘smell and may drink it. Chock with the local authorities about disposing of used antifreeze. Many communities will have collection centres which will ‘antifreeze Is disposed of safely. Caution: At al times use the specified type of antifreeze, and always mix it with istilled water in the correct proportion. The antitrseze contains corrosion inhibitors which are essential to avold damage to the cooling system. A lack of ‘these Inhibitors could lead to @ build-up of corrosion which would block the coolant passages, resulting in overheating and severe engine damage. Distilled water ‘must be used 25 opposed to tap water to avoid a build-up of scale which would also block the passages. thet 2 Pressure cap - check 1 If problems such as overheating ar oss of oglant occur, check the entire eystom ‘desorited in Chapter 1. The filer cap opening Drassure should be checked by a Honda dealer vith the special tester required to do. ‘the job if the cap is defective, renew it. S 3 Coolant reservoir ~ Temoval and installation Removal 1. Tho coolant reservoir is located under the air iter housing behind the engine unit (see 3.1 The coolant reservoir (arrowed) is located under the air filtor housing illustration). Rerrove tho betiery ace Chapter 9), 1901 box, rear mudguard ane rear whee! {see Chapter 7), 2 Helease tha clip cecuting tho broather hove (corning out of the top of the reservoin and detach the hose (sae llustration). Suitable contanor underneath the then reloase the clip securing the radietor overlow hose to the basa of the teservolr. Detach the hose and allow the ‘cooiant to drain into the container. 4 Unscrew the reservoir mounting dol ans Yemave the reservoir. Note haw the lug on the right-hand side locates in the bracket on the ‘ame. Installation 5 Instalation is the reverse of removal. Mala. ‘sure the hoses are correctiy installed and secured with their clips. On completion rt the reservoir as described in Chapter 1 82 Coolant reservoir mounting detailsCooling system 3¢3 ‘48 Disconnect the fan motor wiring ‘connector (arrowed), “4 Cooling fan and cooling fan f aaa ‘replacement Cooling fan Check 41if the engine is overneating and the cooling fan isn't coming on, fst check tne coolant Tiel (800 Daily (oreride) checks}. 1 the level Is correct, check the fan circuit fuse (see Chapter 8) and then the fan switen as escried in Steps 10 to 14 below, 2 ifthe fan doss not come on (and the fen Suiich 1s good), the fault les in thor the coaing fan motor or the relevant wirng. Test allthe wing and connections as described in Chapter 9 3 To test tho cooling fan motor, frat remove the fuel tank (see Chapter 4), Trace the fen motor wiring from the motor and disconnect i at tne 2-pin connactor behind the stearing oad (6 illustration). Using a 12 vot battery and {wo jumper wires. connect the battery fesitve (+ve) lead to the biack/blue motor Wire and the battery negative (ve) ‘ead to farth. Once connected the fan shoul pera. tt does not, then the mater is faulty tm should bo renewed, Replacement Warning: The engine must be completely coo! before carrying ‘ut this procedure. 441 Disconnect the wiring connector (A) trom the fan switch (B) 4.5a Disconnect the wiring connector (A) ‘from the fan switen (3) 4 Remove the radiator (sue Section 7). 8 Disconnect tne wiring connector trom the fan switch (600 llustration). Unserew the three bolts securing the fan shroud and fan assembly to the radiator, noting that one bolt leo sscuras the earth (around) cable, and remove the fan (see illustration) © Unscrew tho three nuts securing the fan ‘essembly to the shroud. 7 Hold the fan with @ rag to provant damage to the blades end unscrow the fan centre nut, Romove the fen from the mator shaft, noting row it fits on the sha © Installation is the reverse of romoval Donot forget io atizch the ezrth (ground) cable, 9 Install the radiator (200 Saction 7), Cooling fan switch Check 40 If the engine Is overheating and the cooling fan isn’t coming on, frst check the Ccaclant eve! (see Daly (pre-ride) checks). if the loval Is correct, check the fan eireult fuse (See Chapter 9). the fuse is blown, chook the fan circut for a short to earth (see the wiring slagrams a the end ofthis book, 11 If the fuse is good, remove the radiator lett-hand side cane! (R, T, V, Wl, X and ¥ models - Chapter 8), and clsconneet the 4.5b Fan assembly mounting bolts (A), tan ‘shroud nuts (B) wiring connector trom the fan switch on the left-nand side of tho radiator (seo llustration). Using a jumpe wireit necessary, connec! tha wire to earth (ground) and turn the ignition ON. If the fan comes on, the ‘itch or the switch connection is defective and must be renewed. If does not come or the fan motor chould bo tasted (e0e Step 3) 12 If the fan stays on all the time, disconnect, the wiring connecter and turn the ignition ON. The fan should stop. If it dees, the svriteh is efsctive and must be renewed. IF it doesn't, check the wring between the switch and the fan for a short to earth, ane the fan motor its 13 If the fan works but Is suspected of cutting in at the wrong temperature, a more Compranerciva test of the witch can be made as foliows. Remove the switch (see Steps 15 to 16). Fil a small heatproot ‘container with coolant and place iton a stove, Connect the positive [+ve) robe of an ‘ohmmeter ‘a the terminal of tre saiteh and the negative (-ve) probe to the ewiton body, Using some wire or other suoport, suspend the switch ip the coolant 89 that Just the sensing portion and the threads aro submorged (see illustration), Also olace a thermometer capabie of reading ternperatares lup to 110°C in the coolant so that its bulb is 4.13. Arrangement for testing the fan swatch3¢4 Cooling system close to the switch. Note: None of the components should be allowed 10 airectly touen the container. 414 Initially the ohmmeter reading should be very high indicating that the switch is open (OFF), Heat the coolant, stiring t gery. Warning: This must be done vory caretully to avoid the risk of ‘personal injury. When the temparaturo roaches cround 98 to 102°C the meter reading should drop to round zero ohms, Indieting thet the switch has cloaod (ON). Now turn tha hoat off. Ae tho temperature falls below’ 99 to 97°C the meter faacing should show infinite (very high) rosictanco, indicating that the switch has ‘pened (OFF), Ifthe meter readings obtained are diferent, or they are obtained at diferent temperatures, then the fan switch is faufty and ‘must be renewed. Replacement A Waring: The engine must be ‘completely cool before carrying ‘out this procedure. 45 Drain the cooling systern (se Chapter 1), 16 Disconnect the wirig connector from the fan ewiteh on tho loft-hand eice of the radiator {see illustration 4.11). Unscrew the switch and withdraw it rom the radiator Discard the O-ring as a new one must be usod, 47 Apoly a suitable sealant te the switch threads, then install the switch using a new ‘O-ring and tightan it to tha torque setting specified at the beainning of this Chapter. ‘Take care not to overtighien te switch as the radiator could be damaged, 18 Reconnect the switch wiring and rotil tho ‘coating system (see Chapter *). Be ripe ee s replacement Coolant temperature gauge Check 41 The circuit consists of the sender mounted {nthe thermostat housing Under the fuel tank, ‘and the gauge mounted in the instrument panel, If the gauge mafunctions, first chock ‘he coolant level (see Daily (pre-ride) checks). If the lovee correct, check that the battery i fully charged and that the fuses are ll good: 2. the gauge Is stl net working, remove the {ual tank (200 Craptor 4). Disconnect the wire from the sender and tur the ianition swteh ON (s2e illustration). The temperature gauge ‘nocd should ben the ’C’ on the gauge. NOW ‘earth the sender wie on the engine. The needie should swing imenediataly over to the ‘H’ on the ‘gauge. if the needle moves as descried, the serdey s detective and must be renewec. Caution: Do not earth the wire for any longer than is necessary to take the reading, or the gauge may be demeged. 8 If the needle movement is stil fauity, oF iit does not move at al, the faut lies in the wiring fr the gauge itself. Chock all the relevant wiring and vriring connectors (s86 Chapter 9). Vall appears to be wet, the gauge s defective ‘and must be renewed. Replacement 4 See Chaoter 9. Temperature gauge sender Check 55 Remove the fuel tank (see Chapter 4) The ‘sondor is mounted in tho thermostat housing. G Disconnect the sender wiring connector (see illustration 5.2). Using a continuity tester, check for continuity between the Sender bacy and earth (ground). There shoud be continuity. there Is no continuity, check that the thermostat mounting is secure, 7 Remove the sender (see Stops 9 and 10 below). Filla small heatproof container with coolant and place it on a stove. Connect the posttive (+ve) probe of an chmmeter to the ‘terminal on the sender and the negative (ve) probe to the sender body (see illustration 4.13). Using some wire of other support, ‘suspend the sender inthe coolant so that just ‘the sensing portion and the threads are suomerged. Alec placo a thormometor capable of reading temperatures up to 120°C in the coolant g0 that Its bulb is close to the sender. Note: None of the components should be allowed to directly touch the contarner. 8 Heat the coolant to approximately 40°C and keep the temperature constant for 9 minutes before continuing the test. Then ineresse tho heat gradually, stiring tho ‘coolant gent, Waring: This mus be done very A Ccaretuhy to avold the Mek of personal ny fa the temperature ofthe coolant sia, the revatance of the vender enculd fal. Check that the coment resistance a obtained tthe temparatures spaced atthe beginning of the Chapter I the meter readings bared are widely different, or they are obtained at Giferent temperatures, then the sender Is fay are must renewed | ‘5.2 Wiring connector (A) and temperature ‘sender (B) Replacement Waraing: The engine must be completely coo! before carrying ut this procedure © Partaly drain the cooling system eutcient ‘to remove the sender without soiling coolant ‘over the engine and cycle parts (see Chap- tert), 10 Disconnect the sender wiring connector Unscren the sender and remove it from the ‘thermostat housing. 14 Apply a suitable sealant to the sender ‘threads, then install it into the thermostat housing and tighton it to the torque setting pected at the beginning of this Chapter Cones the sender wiring. 412. Refill the cooling eystem (00 Chapter 1) 18. Instal the fuel tank (see Chepter 4) & Thermostat and thermostat removal, check and it Removal Warning: The engine must be completely coo! before carrying out this procedure. 1 The thermostat is automatic in operation and should give many years service witheut requiring attention. In the event of a failure, ‘the valv@ will probably jam open, in which feaee the engine will teke much longor than normal to warm up. Conversely if the valve Jams shut, the coolant wil be unable to rculsto and the engine wil overtoat. Nether condition is eeceptable, and the faut must 5 Investigeted prompy 2 Tho thermostct is located in the thermostat hhousing, which Is mounted to the frome uncer the fuel ters 3 Panialy Grain the cooling system sufficient to remove the thermostat and thermosiat housing without spilling cootant over the ‘engine anc cyoie paris (see Chapler 1) 4 Release tho elip securing the ovortiow hoop 40 the radiator filer neck and disconnect hogs, then unscrew the mounting mut for ‘thermostat Housing bracket, acting how te bracket fits (see illustrations). Release tw ‘bracket trom tha rubber shrous, 64a Disconnect the overflow hose from the filer neck...Cooling system 3°5 [a aioe “and unscrew the housing bracket 65a Unscrew the thermostat housing ‘cover baits, 650 ... and withdraw the thermostat 5 Unscrew the two thermostat cover belts ‘and It the cover off the housing. Withdraw the thermostat, noting how it fits (see Mustrations). Discarc the cover O-ring as & ou one must be used. To remove the thermostat housing {sconnect the temperature sender wire anc Siacken tho olipe soouring the hoses to the filer neck and the thermosiat housing anc etach the noses. It necessary, unscrew the two bolts that secure the filler nook to the thermostat cover and discard the Oving as a ew one must be fed, {610 Align hole in thermostat as described and fit new O-ring 6.8 Arrangement for testing tho thermostat Check 7 Examine the thermostat visually before ‘carrying out the test If remains in the open ppositicn at room tomporature, it should be Feneved. 8 Fil a small, hestproot contalner with cole Water and place it on a stove. Using a placa of Wire, euspend the thermostat in the water. Place a thermometer in the water so that the uid |S close to the thermostat (soo ilustration). Heat the water, noting the temperature wiven the thermostat opens, anc compare the result with the specications given at the baginning of this Chapter. Alo Check the amount the valve ooens afte it has been heated at 95°C for a few minutes anc compare tho measurement to tho specifications. If the readings obtained dite from those given, the thermostat is fautty anc ‘must be renowod. 9 In the event of thermostat failure, as an emergency mezsura ony, It can be ramoved land the machino used without it. Nete: Tako care when starting the engine fran cold as it will take much longar than usual to warm up. Ensure that a new unit is installed as soon as possible. Installation 10 Installation is the reverse of removal, using new O-rings. Make sure the thermostat seats correctly witn the hole inthe thermostat facing the laft-hare side of the housing (see lustration). 11 Tighten the bolts 10 the torque settings specifi at the beginning of this Chapter. Thread the bracket through tha rubber shroud ‘anc tighten the dracket mounting nut ane the hhoce clipe securely (see illustration). Gonnect the temperature sender nite. 12 Retll the cookng system (888 Chapter 1) 43 ntal the fuol tank (aee Chapter 4, 6.11 Thread the bracket through the hole inthe rubber shroud (arrowed)3°6 Cooling system 7.3 ... then the upper mounting bott 7-4a Radiator upper mounting lug (arrowed) 4 On A, T,V, W, X end Y models remove the ‘tno radiator side panels; on SW, SX and SY ‘models remove tha fairing (eae Chapter 8) Drain the cooling system (seo Chapter 1). Uncip the stone guard from the front of the radiator 2 Slacken the clips securing the main hoses to the top right-hand side and bottom left-hand side of the raclator and datach the hoses (see illustration), Disconnect the fen ‘wring connector (see illustration 4.3) 3 Unscrew the radiator lower mounting botts, rroting the arrangement of the collar and rubber bushes, and swing the bottom of the raclator forward. Unscrew the radiator ‘upper mounting bolt, noting the arrangement of the collar anc’ rubber bushes (see illustration) 4 ul the redlator o¥ the upper mounting lug and remave the tadiator taking care not to ‘Gamage the rubber shroud Which is held in place by the radictor brackets (see ilustrations). 5 IF necessary, separate the cooling fan (see Seotion 4) from the radiator. fe 7.la_ Unscrew the lower mounting bolt... 7.4b Rubber shroud locates over radiator brackets (arrowed) ue Chock tho stone guard and t sSgns of damage and clea radhator for ny dirt or debris that might obstruct cir ow an inniot cooling (00 Chapter 1). If the radiator fins are badly Camaged or broken the radiator must be Fenawed. Also check the rubber mounting ‘grommets, and renew them if necessary. Installation 7 Instalietion is the roverse of removal, noting the folowing. ‘a Ensure the rubber grommets and collars are correctly installod with the mounting bolls and that the rubber shroud is hnookedt over the urper raciaror rackets 1b) Ensure tho etono guard ie held secuiraly bbyits four mounting cles. ©) Meke sure thatthe fan viring /s correcty ‘connooted. ) Ensure the coolant hoses are in good Cconottion (see Chapter 1), and are ‘securely retained by their clamipe, using nev 079s f necessary 6) On completien ref he ceating system as oscibod in Chapter 1Cooling system 367 181 Pump to crankcase bolts (Al, pump ‘cover bolts (8), carburettor heater hose ‘connection (C) and cooling system 18 Meter nsiantn Check {The water pump fs located on the lower lot-hand sido of the engine (e0e ilustration). Vsualy check the area around the pump for sions of leckage. 2 To prevent leakage of water from the zcing eystom to the lubriestion eystem end vice versa, two seals are ‘tted on the pump Sta On tha underside of tne pump body thore ia cleo a drainago hole. if either seal fas, this hole should allow the coolant or oF ‘a escape and pravent the oll and coolant xg. 8 The pump body is only available as a eompieta assembly. Therefore, if on Inspection the drainage hole showe signe of leakage, the pump must be removed and tena. 8.6 Checking for freeplay on the pump impeller Removal 4 Drain the cooling system (sea Chapter 1), Ramove the front sprocket cover to allow easier access to the hoses. Place a suitable container below the water pump to catch any ‘sidal ol ae tho water pump ie removed. 5 Toremove the pump cover, unscrew the four bolts seounng the cover t0 the pump (the Upper and lower batts also secure the pump to the crankcase), and remove the cover (See lustration 8.1), There no need to detach the hoses unless you want to. Note tho position of each bolt as they ave different lengths. Discard ‘he cover O-ring as a new one must be used. 6 Chack for freeplay botween the pump impeller and the pump body (see illustration). If there is excessive movement the pump ‘must be renawee. Also check for corrosion or 2 build-up of scale in the pump body and Clean or renew the pump as necessary. 7 To tomove the pump body, slacken the clamp securing the covlent hose to the puro bbody and cletach the nose. Carefully draw the Bump from the crankcase, noting how I ie lemeve the O-ring from the rear of the pumo body and discard as a new one must be uses '8 To remove the whole pump a an ascembly, slacken the clamps securing the cockant hoses to te pump cover and body, noting that access ‘tote inner main hoes isreirctod (Gatachitfiom tho engine it it proves stubbom). Detach the 89 Pump body O-ring (A), re was 8a Detach the carburettor heater 8.8 . .. and the hoses from the eylindor block (A) and radiator (8) hhoses, noting which fits where (see ilustrations). Unscrew the two bolts sacuring the pump assembly tothe cankoase (see Stop 5) and carefully craw the pump ou, noting how fs. Remove the O-ring trom the rear ofthe pump ‘body and discard it as a new one rust be used, Separate the cover from the pump if required ‘and discard the O-ring (600 llustration. Installation 9 Apply a smear of clean engine oil to the ump body O-ring and install it onto the rear Of the pump body, then carefully press the ump body into the crankoasa, signing the Blot in the impeller chaft with the oil pump. shaft (see illustration). fot in impeller ehat (B)88 Cooling system 40 Attach the coolant hose to the pump body ‘and secure it with the el. 11 neta! a new O-ring into its groove in the pump body (see illustration), 42 Install the pump cover onto the pump, ‘then install the bolts and tighten them to the torque settings spacified et the beginning of this Chapter. Make sure the diferent length or a small socket bolts are In thelr correct locations (see ilustration) 49 IF cetached, attzeh the coolant hoses to the pump cover and secure them with their clos (see ilustrations 8.8a and b). 14 If the pump was removed as a whole, install the two bolts securing the pump to the crankcase end tighten them to the torque settings specified at the beginning of this Chapter. Attach the coolant hoses to the ump and sacure them with thelr clips (see llustrations 8.8a and). 15 Install the front sprocket cover and refill the cooling system (see Chapter 1). Removal 1 Botora removing a hose, dran the cooling system (see Chepter 1) 2 Use a screwdriver or small socket to 9 Coolant hoses ~ removal and installation 8.12 Pump body bolts (A) are shorter than pump-to-crankcase ‘92¢ Clips on sm: aE ots (6) slacken the larger-bore hose clos, then side them back along tha hose ane clear of the Union spigot. The smaller-bore hoses are secured dy spring clios which can be expanded by squeezing thelr ends together with pliers (08 llustrations). Caution: The radiator unions are fragile. not use excessive force when attempting to ramove the hoses. 9 If a hose proves stubborn, release it by roteting It 09 its union bafore working Ie ff all esa ‘ais, cut the hose with a sharp knile then slit it at each union so that it can be peeled off in two places. Whit this meers Tenewang the hose, it is preferabie to buying now radietor. 4 The coolant pipe inlet union at the front of 1 cylinder diock an the outlet unlon at he rear of the eyindor head can be removed by Uunscrowing the retaining bolts (eee lustrations). Installation 5 Slide the clizs onto the hose and then wok ‘tha hose onto is respective union, -bore hoses can be released with pliersCooling system 399 9.40 . .. and on the back of the head by two belts 6 Rotate the hose on ts unions to settle it in been removed, ti a new O-ting, then install position before sing the cipsinto place and the union and tightan the mounting bolts ‘ightoning them securely, securely (see ilustration) 7 either the inlt union te the cylinder block 8 Reill te cooing syston (see Chapter 1) (r the cutiet union from the cylinder head has 9.7a Fit new O-rings to the front union...