4-14
THERMOSTAT
Removing
1. Drain approximately one quart of coolant from the
cooling system.
2. Remove the two cap screws securing the thermo-
stat housing to the mounting bracket. Remove the
thermostat housing cover and account for an
O-ring and a thermostat.
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 dam-
age.
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
1. Place the thermostat and O-ring into the thermo-
stat housing; then secure the thermostat housing to
the mounting bracket with the two cap screws.
2. Fill the cooling system to the recommended level
with antifreeze. Check for leakage.
WATER PUMP
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.
FI530A
2. Drain the oil from the engine/transmission.
3. Remove the four torx-head cap screws securing
the front and rear fenders to the footrest; then
remove the four cap screws securing the footrest to
the frame. Remove the footrest.
4. Loosen the hose clamps and slide the clamps away
from the hose ends approximately 2 in.; then
remove the hoses from the water pump.
5. Remove the four cap screws securing the water
pump to the engine; then remove the water pump.
FI538A
Installing
1. Secure the water pump to the engine with the four
cap screws tightened to 8 ft-lb.
FI538A
2. Connect the coolant hoses to the water pump and
secure with the clamps. Tighten securely.
Section
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Manual
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