Suzuki Burgman 400 - Service manual > Thermostat

Thermostat Removal and Installation

Removal

1) Drain a small amount of engine coolant. Refer to "Cooling System Inspection".

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

3) Place a rag under the thermostat case (1).

4) Remove the thermostat case (1).

5) Remove the thermostat (2).

Installation

Install the thermostat in the reverse order of removal.

Pay attention to the following points:

• Apply engine coolant to the rubber seal around the thermostat.
• Position the thermostat with one of the air bleeder hole "A" upside.

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

Thermostat Inspection

Inspect the thermostat in the following procedures:

1) Remove the thermostat. Refer to "Thermostat Removal and Installation".

2) Inspect the thermostat pellet for signs of cracking.

3) Test the thermostat at the bench for control action.

! CAUTION

• Do not contact the thermostat (1) and the column thermometer (2) with a pan.
• As the thermostat operating response to water temperature change is gradual, do not raise water temperature too quickly.
• The thermostat with its valve open even slightly under normal temperature must be replaced.

4) Immerse the thermostat (1) in the water contained in a beaker and note that the immersed thermostat is in suspension.

5) Heat the water by placing the beaker on a stove and observe the rising temperature on a thermometer (2).

1. String
2. Water

6) Read the thermometer just when opening the thermostat. If this reading, which is the temperature level at which the thermostat valve begins to open, is out of the standard value, replace the thermostat with a new one.

Thermostat valve opening temperature
Standard: Approx. 82 ºC (180 ºF)

7) Keep on heating the water to raise its temperature.

Just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 3 mm (0.12 in). A thermostat failing to satisfy either of the two requirements (start-to-open temperature and valve lift) must be replaced.

Thermostat valve lift "a"
Standard: 3 mm and over at 95 ºC (0.12 in and over at 203 ºF)

8) Install the thermostat. Refer to "Thermostat Removal and Installation".

See also: