The coolant reservoir (arrowed) is located under the air filter housing

illustration).Remove the battery (see Chapter 9), tool box, rear mudguard and rear wheel (see Chapter 7).

2 Release the clip securing the breather hose (coming out of the top of the reservoir) and detach the hose (see illustration).

3Place a suitable container underneath the reservoir, then release the clip securing the radiator overflow hose to the base of the reservoir. Detach the hose and allow the coolant to drain into the container.

4 Unscrew the reservoir mounting bolt and remove the reservoir. Note how the lug on the right-hand side locates in the bracket on the frame.

Installation

5 Installation is the reverse of removal. Make
sure the hoses are correctly installed and
secured with their clips. On completion refill
the reservoir as described in Chapter 1.

Cooling system 3*3

Disconnect the fan motor wiring connector (arrowed)

A Disconnect the wiring connector (A) from the fan switch (B)

B Fan assembly mounting bolts (A), fan shroud nuts (B)

4 Cooling fan and cooling fan |^>
switch - check and ,

replacement JS

Cooling fan

Check

1 If the engine is overheating and the cooling fan isn't coming on, first check the coolant level (see Daily (pre-ride) checks). If the level is correct, check the fan circuit fuse (see Chapter 9) and then the fan switch as described in Steps 10 to 14 below.

2 If the fan does not come on (and the fan switch is good), the fault lies in either the cooling fan motor or the relevant wiring. Test all the wiring and connections as described in Chapter 9.

3 To test the cooling fan motor, first remove the fuel tank (see Chapter 4). Trace the fan motor wiring from the motor and disconnect it at the 2-pin connector behind the steering head (see illustration).Using a 12 volt battery and two jumper wires, connect the battery positive (+ve) lead to the black/blue motor wire and the battery negative (-ve) lead to earth. Once connected the fanshould operate. If it does not, then the motor is faulty and should be renewed.

4Remove the radiator (see Section 7).

5 Disconnect the wiring connector from the fan switch (see illustration).Unscrew the three bolts securing the fan shroud and fan assembly to the radiator, noting that one bolt also secures the earth (ground) cable, and remove the fan (see illustration).

6Unscrew the three nuts securing the fan assembly to the shroud.

7 Hold the fan with a rag to prevent damage to the blades and unscrew the fan centre nut. Remove the fan from the motor shaft, noting how it fits on the shaft.

8 Installation is the reverse of removal. Do not forget to attach the earth (ground) cable.

9 Install the radiator (see Section 7).

Cooling fan switch

Check

10 If the engine is overheating and the cooling fan isn't coming on, first check the coolant level (see Daily (pre-ride) checks). If the level is correct, check the fan circuit fuse (see Chapter 9). If the fuse is blown, check the fan circuit for a short to earth (see the wiring diagrams at the end of this book).

11 If the fuse is good, remove the radiator left-hand side panel (R, T, V, W, X and Y models - Chapter 8), and disconnect the

wiring connector from the fan switch on the left-hand side of the radiator (see illustration).Using a lumper wire if necessary, connect the wire to earth (ground) and turn the ignition ON. If the fan comes on, theswitch or the switch connection is defective and must be renewed. If it does not come on, the fan motor should be tested (see Step 3).

12 If the fan stays on all the time, disconnect the wiring connector and turn the ignition ON. The fan should stop. If it does, the switch is defective and must be renewed. If it doesn't, check the wiring between the switch and the fan for a short to earth, and the fan motor itself.

13 If the fan works but is suspected of cutting in at the wrong temperature, a more comprehensive test of the switch can be made as follows. Remove the switch (see Steps 15 to 16). Fill asmall heatproof container with coolant and place it on a stove. Connect the positive (+ve) probe of an ohmmeter to the terminal of the switch and the negative (-ve) probe to the switch body. Using some wire or other support, suspend the switch in the coolant so that just the sensing portion and the threads are submerged (see illustration).Also place a thermometer capable of reading temperatures up to 110°C in the coolant so that its bulb is

Date: 2016-01-14; view: 510