Service manual
Page 107 of 151
12-5 System Test
Filler Cap Test
• Hermetically seal the filler cap.
• Apply water and pressure to the filler cap.
• Replace it with new one if it fails to maintain
the specified pressure within a given time
limit, or the opening pressure is too high or
too low.
• The specified pressure should be maintained
at least for 6 seconds in the test.
• Standard pressure for the filler cap: 0.9-0.15 kgf/cm2
• Apply pressure to the radiator, engine and
water hose to check for any leakage
• Pressure which is too high may damage the
radiator. Never use pressure which exceeds
1.05 kg/cm2.
• If the system fails to maintain the specified
pressure for at least 6 seconds, repair or
replace.
Coolant Changing
• Never attempt to carry out service work on the
cooling system unless the engine is completely
cooled down. Serious injury could result.
• Remove the front center cover.
• Remove filler cap.
• Place a water pan under the water pump.
• Loosen the drain bolt to drain out the coolant.
• Reinstall the drain bolt.
• Refill system with coolant and bleed the air
bubbles:
• Run the engine, and remove the by-pass pipe.
• Check by-pass hole for air bubbles to emit.
• If no air (only coolant) flows out, reinstall the by-
pass pipe and shut off the engine.
• Remove the radiator filler cap.
• Start the engine, ensure there are no air
bubbles in the radiator coolant, and ensure the
coolant liquid level is stable.
• Stop the engine. Add coolant to proper level if
necessary.
• Screw in and tighten the radiator filler cap.
• Coolant recommended: SYM Bramax radiator
agent. Concentration: 50%
Coolant reservoir
Radiator filler cap
Drain bolt
Water pump
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