Service Manual

13
2
COOLING SYSTEM
CHECKING COOLING SYSTEM
WARNING: The cooling system is pressurized. Do not remove the radiator cap while the engine is hot. To
avoid scalding hot coolant or steam blowing out of the radiator, use extreme care when removing the radiator
cap. If possible, wait for engine to cool. Wrap a thick rag around cap while removing. To release pressure,
slowly turn cap counter clockwise to the first stop. When all pressure has been released, press down on cap
and continue turning.
Pressure Testing Cooling System
1. Remove radiator cap and make sure coolant is at
correct level.
a. Coolant level must be no more than 25 mm
(1”) below bottom of filler neck.
2. Install cooling system pressure tester on radiator
and pressurize system to 0.75 Bar (11 psi).
3. Check the following for any signs of leaking.
NOTE: System must maintain pressure during
test.
a. Hoses and connections (also check hoses for
excessive bulging).
b. Radiator.
c. Water pump.
d. Freeze plugs (cylinder block and cylinder head).
If system does not maintain pressure and no leaks
are evident externally, check for an internal leak such
as a blown head gasket, warped cylinder head or
cylinder block.
Testing Radiator Cap
Make sure that rubber seal on radiator cap is not
damaged or distorted. Rubber seals must be clean and
free of debris to seal properly.
1. Install radiator cap on pressure tester and
pressurize the cap.
Specification: 1.03 ~ 0.76 Bar (15 ~ 11 psi)
Replace cap if not within specification shown.
NOTE: Recommended pressure cap capacity is
0.9 Bar (13 psi).
CHANGING COOLANT
Coolant should be changed once a year. Change
coolant with engine cold.
1. Remove radiator cap. Remove radiator drain plug
and drain the system, Fig. 1.
Fig. 1 – Draining Coolant
DRAIN PLUG
Fig. 2 – Adding Coolant
25 mm (1”)
2. Tighten drain plug.
NOTE: Follow state or federal laws regarding the
proper procedure for disposing of anti-
freeze.
3. Fill radiator with 50% solution of phosphate free
antifreeze.
4. Start and run engine until thermostat opens (when
coolant level drops, thermostat is open).
5. Check coolant level in radiator and add coolant as
required, Fig. 2.