Service Manual (KLZ1000C) — page 147 of 762

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COOLING SYSTEM 4-1

                                        Cooling System
                                                       Table of Contents
Exploded View........................................................................................................................          4-2
Coolant Flow Chart.................................................................................................................            4-4
Specifications .........................................................................................................................       4-6
Special Tools .........................................................................................................................        4-7
Coolant ...................................................................................................................................    4-8
   Coolant Deterioration Inspection.......................................................................................                     4-8   4
   Coolant Level Inspection...................................................................................................                 4-8
   Coolant Draining ...............................................................................................................            4-8
   Coolant Filling ...................................................................................................................         4-8
   Pressure Testing ...............................................................................................................            4-8
   Cooling System Flushing ..................................................................................................                  4-9
   Coolant Reserve Tank Removal .......................................................................................                        4-9
   Coolant Reserve Tank Installation ....................................................................................                      4-9
Water Pump............................................................................................................................        4-10
   Water Pump Removal .......................................................................................................                 4-10
   Water Pump Installation ....................................................................................................               4-10
   Water Pump Inspection.....................................................................................................                 4-12
   Water Pump Impeller Disassembly/Assembly ..................................................................                                4-12
   Water Pump Impeller Inspection .......................................................................................                     4-12
   Water Pump Housing Disassembly ..................................................................................                          4-12
   Water Pump Housing Assembly .......................................................................................                        4-13
   Mechanical Seal Inspection ..............................................................................................                  4-13
Radiator ..................................................................................................................................   4-14
   Radiator and Radiator Fan Removal ................................................................................                         4-14
   Radiator and Radiator Fan Installation .............................................................................                       4-16
   Radiator Inspection ...........................................................................................................            4-17
   Radiator Cap Inspection ...................................................................................................                4-17
   Radiator Filler Neck Inspection .........................................................................................                  4-18
Thermostat .............................................................................................................................      4-19
   Thermostat Removal.........................................................................................................                4-19
   Thermostat Installation......................................................................................................              4-19
   Thermostat Inspection ......................................................................................................               4-20
Hose and Pipes ......................................................................................................................         4-21
   Hose Installation ...............................................................................................................          4-21
   Hose Inspection ................................................................................................................           4-21
Water Temperature Sensor ....................................................................................................                 4-22
   Water Temperature Sensor Removal/Installation .............................................................                                4-22
   Water Temperature Sensor Inspection .............................................................................                          4-22