Suzuki Burgman 400 - Service manual > Cooling Circuit, Radiator

Cooling Circuit Inspection

! WARNING

• Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor.
• When removing the radiator cap tester, put a rag on the filler to prevent the engine coolant from spraying out.

Inspect the cooling circuit in the following procedures:

1) Remove the handlebar covers. Refer to "Handlebar Cover Removal and Installation".

2) Remove the front panel. Refer to "Front Panel Removal and Installation".

3) Remove the radiator cap (1) and connect the radiator tester (2) to the filler.

4) Pressurize the cooling system with 120 kPa (1.2 kgf/ cm, 17 psi) of pressure, and then check if it holds the pressure for 10 seconds.

5) If the cooling system does not hold the pressure for at least 10 seconds, check the entire cooling system for leaks and replace the damaged part.

6) Install the front panel. Refer to "Front Panel Removal and Installation".

7) Install the handlebar covers. Refer to "Handlebar Cover Removal and Installation".

! CAUTION Do not exceed the radiator cap release pressure, or the radiator cap and subsequently the radiator, can be damaged.

Radiator Cap Inspection

Inspect the radiator cap in the following procedures:

1) Remove the radiator cap. Refer to "Cooling Circuit Inspection".

2) Attach the radiator cap (1) to the radiator tester (2) as shown.

3) Slowly apply pressure to the radiator cap.

4) If the radiator cap does not hold the pressure for at least 10 seconds, replace it with a new one.

Radiator cap release pressure
93.3 - 122.7 kPa (0.93 - 1.23 kgf/cm2, 13.3 - 17.4 psi)

Radiator Removal and Installation

Removal

1) Remove the lower leg shield. Refer to "Lower Leg Shield Removal and Installation".

2) Remove the left and right footboards. Refer to "Footboard Removal and Installation".

3) Drain engine coolant. Refer to "Cooling System Inspection".

4) Remove the radiator outlet hose (1).

5) Disconnect the cooling fan motor coupler (2) and radiator heat shields (3).

6) Disconnect the conduction hose (4) and remove the radiator mounting bolts.

7) Disconnect the radiator inlet hose (5) and remove the radiator (6).

Installation

Install the radiator in the reverse order of removal. Pay attention to the following points:

• Pour engine coolant. Refer to "Cooling System Inspection".
• Bleed air from the cooling circuit. Refer to "Cooling System Inspection".

Radiator Cleaning

Clean the radiator in the following procedures:

1) Remove the radiator. Refer to "Radiator Removal and Installation".

2) Remove the cooling fan. Refer to "Cooling Fan Removal and Installation ".

3) Inspect the radiator for dirt and other foreign materials.

4) Clean the radiator using compressed air.

5) Repair any bent or dented fins using a small screw driver.

Radiator Hose Inspection

Inspect the radiator hoses in the following procedures:

1) Remove the left footboard. Refer to "Footboard Removal and Installation".

2) Remove the air cleaner box. Refer to "Air Cleaner Box Removal and Installation".

3) Remove the radiator mounting bolts. Refer to "Radiator Removal and Installation".

4) Inspect the radiator hoses for crack or flat and leakage of hose connection.

If any radiator hose found in a cranked condition or flattened must be replaced. Refer to "Radiator Hose Removal and Installation ".

If any leakage from the connecting section should be corrected by proper tightening.

Radiator Hose Removal and Installation

Removal

1) Drain engine coolant. Refer to "Cooling System Inspection ".

2) Remove the left footboard. Refer to "Footboard Removal and Installation".

3) Remove the air cleaner box. Refer to "Air Cleaner Box Removal and Installation ".

4) Remove the radiator mounting bolts. Refer to "Radiator Removal and Installation".

5) Remove the required radiator hose.

Installation

Install the radiator hose in the reverse order of removal.

Pay attention to the following point:

• Rout the radiator hose properly. Refer to "Radiator Hose Routing Diagram".

Radiator Reservoir Tank Removal and Installation

Removal

1) Remove the front leg shield. Refer to "Front Leg Shield Removal and Installation ".

2) Remove the reservoir tank bracket bolt.

3) Disconnect the hoses and remove the reservoir tank (1).

4) Remove the bracket (2).

Installation

Install radiator reservoir tank in the reverse order of removal. Pay attention to the following point:

• Fill the reservoir tank to the upper level.

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