Kawasaki J300 - Service manual > Thermostat

Thermostat Removal

• Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).
• Remove the storage box (see Storage Box Removal in the Frame chapter)
• Loosen the water hose clamp screw [A].
• Disconnect the water hose [B].
• Remove:
  Thermostat Housing Cover Bolts [C]
  Thermostat Housing Cover [D]
  Thermostat

Thermostat Installation

• Install the thermostat [A] in the housing so that the air bleeder hole [B] is on top.
• Install the thermostat cover, and tighten its bolts.

  Torque - Thermostat Housing Cover Bolts: 7.4 N*m (0.75 kgf*m, 65 in*lb)

• Install the water hose and tighten the clamp screw.

  Torque - Water Hose Clamp Screw: 4.4 N*m (0.45 kgf/cm, 39 in*lb)

• Install the removed parts (see appropriate chapters).

Thermostat Inspection

• Remove the thermostat (see Thermostat Removal).
• Inspect the thermostat valve [A] at room temperature.

  If the valve is open, replace the thermostat with a new one.

• To check valve opening temperature, suspend the thermostat [A] in a container of water and raise the temperature of the water.
  • The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth.

    It must not touch the container, either.

  If the measurement is out of the specified range, replace the thermostat with a new one.

Thermostat Valve Opening Temperature
 71ºC (160ºF)

Hoses and Pipes

Hose Installation

• Install the hoses, being careful to follow bending direction.

  Avoid sharp bending, kinking, flattening or twisting.

• Run the hoses (see Cable, Wire, and Hose Routing section in the Appendix chapter).
• Install the clamp [A] as near as possible to the hose end to clear the raised rib of the fitting. This will prevent the hoses from working loose.
  • The clamp screws should be positioned correctly to prevent the clamps from contacting the other parts.

Hose Inspection

• Refer to the Radiator Hose and Pipe Inspection in the Periodic Maintenance chapter.

Water Temperature Sensor

Water Temperature Sensor (ECU) Removal/Installation

• Refer to the Water Temperature Sensor (ECU) Removal/ Installation in the Fuel System (DFI) chapter.

Water Temperature Sensor (Meter) Removal

• Remove the intake manifold (see Intake Manifold Removal in the Engine Top End chapter).
• Disconnect the water temperature sensor connectors [A].
• Remove:
  Water Temperature Sensor [B]
  Terminal Plate [C]

Water Temperature Sensor (Meter) Installation

• Installation is the reverse of removal.
• Apply liquid gasket to the threads of the water temperature sensor, and tighten it together with the terminal plate.

Sealant - Liquid Gasket, TB1211F: 92104-0004

Torque - Water Temperature Sensor (Meter): 7.4 N*m (0.75 kgf*m, 65 in*lb)

• Connect the connectors.
• Install the intake manifold (see Intake Manifold Installation in the Engine Top End chapter).

Water Temperature Sensor Inspection

• Refer to the Water Temperature Sensor Inspection in the Electrical System chapter.

See also: