4-14
4. Install the front bumper and front fender panel.
5. Install the front rack.
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 (H1)
1. Drain approximately one quart of coolant from the
cooling system.
2. Remove the two cap screws securing the thermo-
stat housing to the cylinder head. Account for an
O-ring and a thermostat.
Removing (H2)
NOTE: The thermostat is located in a housing
in-line with the upper radiator hoses under the air
filter housing.
GZ036A
1. Drain approximately one quart of coolant from the
cooling system.
2. Remove the machine screws securing the thermo-
stat housing together. Remove the thermostat and
account for an O-ring.
Inspecting
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.
1. Inspect the thermostat for corrosion or spring damage.
2. Using the following procedure, inspect the ther-
mostat 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 (H1)
1. Place the thermostat and O-ring into the thermo-
stat housing; then secure the thermostat housing to
the cylinder head with the two cap screws.
2. Install the crossover coolant hose onto the water
pump and engine water inlet. Secure with the two
hose clamps.
3. Slide the upper hose onto the thermostat housing
and radiator. Secure with the two hose clamps.
4. Install the lower coolant hose onto the water pump
housing and radiator. Secure with the two hose
clamps.
5. Fill the cooling system with the recommended
amount of antifreeze. Check for leakage.
Installing (H2)
1. Place the thermostat and O-ring into the thermo-
stat housing; then secure the thermostat housing
together with the four machine screws.
2. Fill the cooling system with the recommended
amount of antifreeze. Check for leakage.
COOLING FAN
Removing
1. Remove the radiator (see Liquid Cooling System
in this section).
2. Remove the fan assembly from the radiator.
Installing
1. Position the fan assembly on the radiator; then
secure with existing hardware.
NOTE: The fan wiring must be in the upper-right
position.
2. Install the radiator.
WATER PUMP (H1)
NOTE: The water pump is a non-serviceable
component. It must be replaced as an assembly.
Removing
1. Remove the radiator cap; then remove the water
pump drain and drain the coolant.
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