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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