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CC863
Cleaning and Inspecting
1. Flush the radiator with water to remove any contaminants.
2. Inspect the radiator for leaks and damage.
3. Inspect all hoses for cracks and deterioration.
4. Inspect all fasteners and grommets for damage or wear.
Installing
1. Position the fan/fan shroud assembly on the radiator;
then secure with existing hardware.
2. Place the radiator with grommets and collars into
position on the frame; then install the cap screws and
nuts. Tighten securely.
3. Install the upper and lower coolant hoses; then
secure with hose clamps.
AF734D
4. Install the front bumper and front fender panel (see
Steering/Frame/Controls).
5. Install the front rack (see Steering/Frame/Controls).
6. Fill the cooling system with the recommended
amount of antifreeze. Check for leakage.
7. Connect the fan wiring to the main wiring harness.
THERMOSTAT
Removing (500/550/700)
1. Drain approximately one quart of coolant from the
cooling system.
2. Remove the two cap screws securing the thermostat
housing to the cylinder head. Account for an O-ring
and a thermostat.
Removing (1000)
NOTE: The thermostat is located in a housing
in-line with the upper radiator hoses under the air fil-
ter housing.
GZ036A
1. Drain approximately one quart of coolant from the
cooling system.
2. Remove the machine screws securing the thermostat
housing together. Remove the thermostat and
account for an O-ring.
Inspecting
1. Inspect the thermostat for corrosion or spring dam-
age.
2. Using the following procedure, inspect the thermo-
stat for proper operation.
A. Suspend the thermostat in a container filled with
water.
B. Heat the water and monitor the temperature
with a thermometer.
C. The thermostat should start to open at 71-86° C
(160-187° F).
D. If the thermostat does not open, it must be
replaced.
3. Inspect all coolant hoses, connections, and clamps
for deterioration, cracks, and wear.
NOTE: All coolant hoses and clamps should be
replaced every four years or 4000 miles.
Installing (500/550/700)
1. Place the thermostat and O-ring into the thermostat
housing; then secure the thermostat housing to the
cylinder head with the two cap screws.
2. Fill the cooling system with the recommended
amount of antifreeze. Check for leakage.
