Kawasaki J300 - Service manual > Radiator

Radiator and Radiator Fan Removal

• Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
• Remove:
  Front Fairing (see Front Fairing Removal in the Frame chapter)
  Side Fairing (see Side Fairing Removal in the Frame chapter)
  Radiator Cover (see Radiator Cover Removal in the Frame chapter)
  Lower Cover (see Lower Cover Removal in the Frame chapter)
• Disconnect the radiator fan motor lead connector [A].

• Loosen the water hose clamp screws [A].
• Disconnect the water hoses [B].

• Loosen the water hose clamp screw [A].
• Disconnect the water hose [B].
• Remove:
  Radiator Bolts [C]
  Radiator [D]

NOTICE Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.

• Remove:
  Radiator Fan Bracket Bolts [A]
  Radiator Fan Bracket [B]
  Radiator Fan Screws [C]
  Radiator Fan [D]

Radiator and Radiator Fan Installation

• Installation is the reverse of removal.
• Insert the projection [A] of the frame into the grommet [B] of the radiator.
• Tighten:
  Torque - Water Hose Clamp Screws: 4.4 N*m (0.45 kgf/cm, 39 in*lb)
• Install the removed parts (see appropriate chapters).

Radiator Inspection

• Remove the radiator (see Radiator and Radiator Fan Removal).
• Check the radiator core.

  If there are obstructions to air flow, remove them.

  If the corrugated fins [A] are deformed, carefully straighten them.

  If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.

NOTICE When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: Keep the steam gun [A] away more than 0.5 m (1.6 ft) [B] from the radiator core.

Hold the steam gun perpendicular [C] (not oblique [D]) to the core surface.

Run the steam gun, following the core fin direction.

Radiator Cap Inspection

• Remove:
  Front Center Cover (see Front Center Cover Removal in the Frame chapter)
  Radiator Cap
• Check the condition of the bottom [A] and top [B] valve seals and valve spring [C].

  If any one of them shows visible damage, replace the cap with a new one.

• Install the cap [A] on a cooling system pressure tester [B].

NOTE

• Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.

 

• Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle flicks downward. Stop pumping and measure leak time at once. The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range for at least 6 seconds.

Radiator Cap Relief Pressure
 Standard: 88 +-14 kPa (0.9 +-0.15 kgf/cm², 13 +-2 psi)

If the cap can not hold the specified pressure or if it holds too much pressure, replace it with a new one.

Radiator Filler Neck Inspection

• Remove:
  Front Center Cover (see Front Center Cover Removal in the Frame chapter)
  Radiator Cap
• Check the radiator filler neck for signs of damage.
• Check the condition of the top and bottom sealing seats [A] in the filler neck. They must be smooth and clean for the radiator cap to function properly.

See also: