CONTENTS ~COOLING SYSTEM COOLING SOLuTjON

_
1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-

. . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5_ 3

RADIATOR AND WATER HOSES THERMOSTAT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 6

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 7 THERMO-S WITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *5-10 !_NS!=EC?!G_N AND D!SA SSE_MBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- !O FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . **5- 11 TEMPERATURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-71

5-l

COOLING

SYSTEM

COOLING SYSTEM
DESCRIPTION
The engine is cooled is a tube-and-fin head dissipation. The thermostat is of wax pellet type, through in the pellet. illustration, the thermostat is in the closed condition, so that water recirculates _ complete with a valve as the means of temperature-dependent The valve is actuated by the temperature-sensitive by coolant set in forced recirculation material, through jackets formed in the cylinder and head, and through the radiator. For the water pump, a high-capacity centrifugal pump is used. The radiator

type made of aluminum

which is characterized

by lightness in weight and good

control

over the flow of coolant

the radiator.

wax contained Referring through condition.

As

to the following

the route comprising

pump, engine, by-pass holes of the thermostat

and radiator in the regulated

the coolant

temperature

rises to 75C

and the thermostat

valve unseats, the normal coolant becomes completely

flow is

established.

At about 90C of coolant temperature,

the thermostat

open and most of

heat is released to the atmosphere through the radiator core.

Reservoir

tank

Thermostat

COOLING SYSTEM 5-2

COOLING SOLUTION
Water 50% 850 ml (1.811.5 850 ml (1.8/l US/imp. pt) pt)

At the time of manufacture, a 50 : 50 solution coolant. protection, This of distilled 50 : 50

the cooling system is filled with water and anti-freeze/summer will F). to temperatures below
.'E E F .= 2

Coolant

.5 US/Imp.

mixture

provide

excellent

heat ( F) 1C)
302,150 284.140 266.130 248.120 230.110 212 i100 0 10 20 30 40 50 60 (kg/cd)

and will protect above -31C this mixing

the cooling system from freezing (-24

at temperatures -31C (-24F),

If the motorcycle

is to be exposed

ratio should be increased up to

55% or 60% according to the Fig. 2. NOTE: The characteristics of different anti-freezes vary. Read the label to know the protection CAUTION: Do not put in more than 60% anti-freeze not mix different brands of anti-freeze. or less than 50%. Do you will have.

Density (%)

Fig. 1 Coolant density-boiling point curve.

IoF) ( c)
32 0 14 1 -10 -4 i -20

E
6
P

-22. -30 -40+ -40 -58. -50

P .: I;

ii

20

40

60

80

loo

Density (%)

Fig. 2 Coolant density-freezing point curve.

5-3 COOLING

SYSTEM

RADIATOR AND WATER HOSES

Radiator Radiator Radiator Radiator Coolant Radiator cap hose inlet hose reservoir overflow hose

Thermo-switch Temperature Cooling fan Fan motor switch

INSPECTION
Before inspect removing the radiator items. system
I

and draining for tightness

the

the cooling

solution,

the following

1.Test the cooling toctor 1c fnlln\n/c.

L.,LUI -1
IVII.

by using the radiator of about fall 1.2 kg/cm* this lo-

Rommm
.UIIIU

priiatnr and rnnnnrt ..UlUL..l c-21-1 V-y, Ull .,ImllrL the _,I%.,

tester for

to

the

filler.

Give

a pressure should

(17 psi, 120 kP a ) and see if the system 10 seconds. interval, If the pressure it means that or part. relieving second system. 2. Test tester, the with found the there

holds this pressure during point in the

is a leaking

In such a case, inspect radiator tester as shown, Make tester for cap for and build sure that held

the entire

system and replace by using the

the leaking component radiator

pressure

in the following

manner:

Fit the cap to the by operating stops at of that build-up

up pressure slowly the pressure

tester. the

1.1 ? 0.15 kg/cm* pressure

(15.6 f 2.1 psi, 110 + 15 kPa) and that, standstill, the cap is capable Replace 10 seconds. the cap if it is
0 Radiator cap tester @ Radiator cap

at least

not to satisfy

either

of these two requirements. I

Radiator cap valve release pressure : 1.1 f 0.15 kg/cm* (15.6 f 2.1 psi, 110 + 15 kPa)

3. Road dirt bent down with 4. Any should water

or trash stuck or dented hose found Any

to the fins must be removed. for this cleaning. by straightening condition

Use Fins them

of compressed

air is recommended can be repaired in a cracked leakage from

the blade of a small screwdriver. or flattened section the connecting

must be replaced. be corrected

by proper

tightening,

REMOVAL
1. Drain the cooling 2. Remove solution by removing the drain plug (j). tank. the radiator hoses, radiator and reservoir

INSTALLATION
The radiator is to be installed After installing in the reverse order of the removal coolant: procedure. the radiator, be sure to add

refer to page 2-10 for refilling

information.

Align the white painted marks.

Cla

Align the white d marks.

Clip Cla& / \\ ,, / Clamp Clip Air bleeder plug rl / \ \ W \ \ _

Clamp

Thermoswitch

i v\._-\

Align the white painted mark on the radiator hose

btting

aIIow*-

Clamp

Tightening ITEM Air bleeder

torq ue N.m plug Thermo-switch IO-12 9-14 kg-m 1 .O0.9-1.4 1.2 lb-ft 7.0-8.5 6.5-10.0

COOLING SYSTEM 5-6

THERMOSTAT
REMOVAL
1. Drain the coolant. 2. Remove the secondary 3. Remove the gearshift 09900-06107 case cover. lever by removing the snap ring.

: Snap ring pliers

4. Disconnect 5. Disassemble be free.

the

radiator

hose and remove assembly.

the water will

pump then

cover assembly. the cover The thermostat

INSPECTION
Inspect Test the thermostat thermostat manner. between flange, as shown in the illustration. contained water by in a beaker, therthe on a
+n

pellet at the

for signs of cracking. bench for control action, in the

the

following Immerse

Pass a string as shown mostat beaker

the thermostat in the is in suspension.

in the water Heat the

illustration.

Note that

the immersed placing

0
D Thermostat @ String

on a stove

and observe

the rising temperature

thn

thermometer, RnzxA inert I I_ thn t.II\r tharmnmntnr CIIk,,llI IIIGL%.I , .aL \rrhan IIGII the bottom ture should level of the pan. This at which the between thermostat 73.5 C LII-Z thnrmnrtcat CI1cz1III JL L rlrnnc u1vp.l which valve begins L

reading,

is the temperato open,

be anywhere

(164.3 F) and 76.5 C

(169.7 F). Thermostat

l

vaive opening temperature the water

: 75.0 + 1.5C to and I

D Stove @ Thermometer

Keep on heating beyond

(167 f 2.7 F) to raise its temperature

90C (194F). the water reaches 90C (194 F), the thermostat

Just when valve should

have lifted

by at least 6.0 mm (0.24 in).

Thermostat

valve lift : Over 6.0 mm at 90C (Over 0.24 in at 194 F)

A thermostat ments replaced.

failing

to satisfy either temperature

of the two lift)

requiremust be

(start-to-open

and valve

WATER PUMP

Radiator Water Water O-ring Pin Impeller Impeller Mechanical Oil seal Bearing E-ring Gasket Thermostat

hose connector cover

pump pump

shaft seal

REMOVAL
1. Refer to page 5-6 for the water pump 2. Remove the water pump cover. 3. Remove the magneto of the impeller rotor. 4. Remov e the three screws securing water pump assembly. cover plug, then set the three openings the generator to the three screws by rotating removal procedures.

5. Set

one of

the

openings rotor.

to

an unused

femaie

screw

by

rotating

the generator

6. Drive out the water pump assembly by threading screw into the female screw.

a removed

INSPECTION AND DISASSEMBLY

WATER Turn the PUMP BEARING impeller and check the bearing play. is noted, If abnormal replace the

noise occurs or any sign of stickiness bearing with a new one.

l

Remove the E-ring.

Pull out the impeller shaft.

@ Bemove the impeiier from the impeiier shaft.

Remove the water pump bearing by using the special tools. : Sliding shaft : Bearing remover

09930-30102 09921-20200 CAUTION:

The removed bearing should be replaced with a new one.

MFCHANICAI m..__ ..,. mm._,._

SFAI .__,

Visually attention

inspect the mechanical seal for damage, with particular given to the sealing face. Replace the mechanical seal of leakage. Also replace the oil seal if seal with care to prevent damage

that shows indications necessary.

l

Gouge out the mechanical to the stuffing box.

5-9 COOLING SYSTEM

Gouge out the oil seal.

CAUTION: The removed mechanical seal or oil seal should be replaced with a new one.

REASSEMBLY
Reassemble of
l

and remount and

the water

pump

in the reverse order to the following

removal Install

disassembly.

Pay attention

points: the bearing using the special tool.

Apply

grease to the oil seal lip before model) : SUZUKI SUPER SijPEFi

installing.

(For U.S.A. 99000-25030

GREASE GREASE

A A -

(For the other models) 99000_250io : siizui(i

Press the oil seal into sleeve etc.

the stuffing

box using a suitable

size

Press the suitable

mechanical

seal

into

the

stuffing

box

using

size sleeve etc.

Replace pump.

O-rings

with

new ones when reassembling

the water

NOTE: Seat ring of the mechanical seal must be assembled with marked face of the ring toward the impeller.

COOLING SYSTEM 5-10

THERMO-SWITCH
The cooling fan, being located behind the radiator, motor motion. is automatically controlled of coolant is low, but it closes at about 105C is secured to the radiator by three bolts. The fan drive This switch remains open when the temperature of rising water temperature to set the fan in (221F) by the thermo-switch.

1
Fuse R R lg. switch Fan motor Thermoswitch R 7 B/W x B I I

Battery

INSPECTION
THERMO-SWITCH
l

Disconnect The

the thermo-switch from the radiator. must

lead wires and remove the for its temperaturevalue of 105C

thermo-switch
l

thermo-switch by testing

be checked

initiated (221F) Connect

closing action

at the specification

it at the bench as shown in the figure.

the switch to a circuit tester and raise the tempera-

ture of the oil in the pan, and read the column thermometer when the switch closes.

OFF ON NOTE:

ON

Approx. Approx.

105C 100C

(221F) (212F)

-+ OFF

Do not forget the O-ring. Tightening torque : 9.0 (0.9 14 N-m 1.4 kg-m, 6.5 - 10.0 lb-ft)

Thermo-switch

CAUTION: -I-..,,,. . . . . . . . mm,. ..hP... t......el,:.... r...:*..ls I an= JpJciblal ulrr; . Wllcill llclllUllll$j +L... L,ltz +L...,-.. L,,ci,111 -Jvv,Lw,. cause damage if thermo-switch gets a sharp impact.

I& IL --.. ,,,ay

FAN MOTOR
Test the cooling fan drive motor for load current meter and an ammeter connected The voltmeter running is for making With volts to the motor. more than 5 amperes. If the fan motor with a new one. does not turn, replace the motor assembly sure that the battery with should electric with a voltapplies 12 motor fan not as shown in the illustration.
7 I A-Battery

the motor

at full speed, the ammeter

be indicating

TEMPERATURE SWITCH
REMOVAL
l

Remove the temperature

switch after disconnecting

the lead

wires in the headlight housing.

INSPECTION
The temperature initiated (243F) Connect closing switch must be checked for its temperatureaction at the specification value of 117C

by testing it at the bench as shown in the illustration. the switch to the pocket tester and raise the temperathermometer

ture of the oil in the pan, and read the column when the switch closes. 09900-25002 Temperature OFF ON : Pocket tester switch specification + ON Approx. Approx. 117C 110C

(243 F) (230 F)

-+ OFF

REASSEMBLY
NOTE: Do not forget the O-ring. Tightening Temperature torque switch : 10 15 N-m 11 .O lb-ft) (I .O - 1.5 kg-m, 7.0 CAUTION: Take special care when handling a sharp impact. Fill the specified coolant (See page 2-10). the temperature switch. It may cause damage if temperature switch gets