110
5. Remove the cap screws and nuts securing the radia-
tor to the frame.
6. Disconnect the fan wiring from the main wiring har-
ness; then remove the radiator/fan assembly and
account for the grommets and collars.
7. Remove the fan/fan shroud assembly from the radiator.
CC863
CLEANING AND INSPECTING
1. Flush the radiator with water to remove any contami-
nants.
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.
Hoses/Thermostat
REMOVING
1. Drain approximately two quarts of coolant from
the cooling system.
2. Remove the two cap screws securing the thermostat
cover housing to the thermostat housing. Account for
an O-ring and a thermostat.
INSPECTING
1. Inspect the thermostat for corrosion, wear, or spring
damage.
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 80° C (176°
F) and be fully open at 95° C (203° F).
D. If the thermostat does not open or remains 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
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. 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.
Fan
REMOVING
1. Remove the radiator (see Radiator 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.
