New antifreeze, distilled water, and clean drain pan at the ready |
Remove the allen screw on both sides of the lower cowl |
Remove the allen screw on the upper portion of the lower cowl, both sides |
Pull out both plastic pop rivets |
Pop rivet pulled free |
Remove the lower allen screws, on both sides |
Pull the black plastic portion forward to allow the lower cowl to slip out |
Carefully pull the tab out from under the fairng side panel. The plastic will give enough to allow you to flew it some |
By grasping the side of the fairing side panel, you can pull it out just enough to free the tab for the lower cowl |
Here you can see the lower cowl pulled free from the black plastic upper cover |
Now you need to remove the right fairing pocket. |
Disconnect the lock cable |
Now you can access the radiator cap |
Take the cap off so the fluid can drain |
Here is the drain plug. It is a 8mm bolt inside the round port. |
Simply unbolt it with a 8mm socket |
And out comes the fluid |
It may take as much as 15 minutes to fully drain, as it trickles out pretty slow. |
Once you have it all out, put the bike on the side stand and you should be able to get some more. |
Here is a look at the bolt that hold the overflow reservoir in place |
Remove the bolt. |
And pull down and to the right on the reservoir to remove |
Disconnect the two hoses on the top of the reservoir |
Here is the grimy reservoir after it is free. Drain, clean, and refill it before you reinstall it. |
Here is a sheet of alluminum I bought at Lowes for $5 to make a shield out of for the reservoir bottom. |
Size and cut the sheild to fit |
I bent it so that it would hold onto the reservoir |
From the side, you can see the sheild bent around the reservoir. |
Here is a look at the bottom |
Sheild installed |
And refilled with new coolant |
I used a bit of safety wire to hold the fron edge of the sheild in place. The wire runs up around the top of the reservoir |
Here is my foolproof way of mixing antifreeze. Use a graduated flask and fill to a set point (500 cc's is used here) |
Now pour that in a clean container. |
Fill the flask back to the same point with distilled water. |
And pour that into the container. Keep repeating until the container is nearly full. |
I also added 3.5 ounces of Water Wetter to the system to help cooling. This is purely optional, but I like this stuff. |
Now just fill the system. Pour slowly, as it won't accept the fluid very fast. Notice the new fluid color matches my bike :^) |
Once you have it full, run the engine and snap the throttle to burp out any trapped air. Then top off the system. |
The Great Pumpkin Rides Again! |
DCP_1086.JPG |
DCP_1088.JPG |
Field repair of coolant overflow tank using JB Weld |
100_1488.jpg |
Leak 003.jpg |