5.2 Wiring connector (a) and temperature sender (b)

As the temperature of the coolant rises, the resistance of the sender should fall. Check that the correct resistance is obtained at the temperatures specified at the beginning of this Chapter. If the meter readings obtained are widely different, or they are obtained at different temperatures, then the sender is faulty and must be renewed.

Replacement

A Warning: The engine must be completely cool before carrying out this procedure.

9 Partially drain the cooling system sufficient to remove the sender without spilling coolant over the engine and cycle parts (see Chap­ ter 1).

10. Disconnect the sender wiring connector. Unscrew the sender and remove it from the thermostat housing.

11. Apply a suitable sealant to the sender threads, then install it into the thermostat housing and tighten it to the torque setting specified at the beginning of this Chapter. Connect the sender wiring.

12. Refill the cooling system (see Chapter 1).

13. Install the fuel tank (see Chapter 4).

6 Thermostat and thermostat housing - removal, check and || installation ^

Removal

A Warning: The engine must be completely cool before carrying out this procedure.

6.4a Disconnect the overflow hose from the filler neck ...

1. The thermostat is automatic in operation and should give many years service without requiring attention. In the event of a failure, the valve will probably jam open, in which case the engine will take much longer than normal to warm up. Conversely, if the valve jams shut, the coolant will be unable to circulate and the engine will overheat. Neither condition is acceptable, and the fault must be investigated promptly.

2. The thermostat is located in the thermostat housing, which is mounted to the frame under the fuel tank.

3. Partially drain the cooling system sufficient to remove the thermostat and thermostat housing without spilling coolant over the engine and cycle parts (see Chapter 1).

4. Release the clip securing the overflow hose to the radiator filler neck and disconnect the hose, then unscrew the mounting nut for the thermostat housing bracket, noting how the bracket fits (see illustrations). Release the bracket from the rubber shroud.

Cooling system 3»5

6.4b ... and unscrew the housing bracket nut

6.5A Unscrew the thermostat housing cover bolts ...

6.5B ... Lift off the cover .

THERMOMETER

THERMOSTAT

6.5C ... And withdraw the thermostat

5. Unscrew the two thermostat cover bolts and lift the cover off the housing. Withdraw the thermostat, noting how it fits (see illustrations). Discard the cover O-ring as a new one must be used.

6. To remove the thermostat housing, disconnect the temperature sender wire and slacken the clips securing the hoses to the filler neck and the thermostat housing and detach the hoses. If necessary, unscrew the two bolts that secure the filler neck to the thermostat cover and discard the O-ring as a new one must be fitted.