Bypass Pipe Removal
1. Remove the Circ lip from the Groove.
Push the Bypass Pipe down.
eRemove the thermostat
and the spring and the
thermostat come out on cover removal.
ePul1 off the bypass
and replace the
it with new ones. Apply a little coolant to them to
elnsert the bypass pipe completely into the water pump
cover with the circlip groove going into the cover.
A. Bypass Pipe
ePut the circlip on the bypass
NOTE: The circlip need not be installed this stage.
It will be set in the groove after installation of the
elnstall the thermostat,
new gasket, and thermo-
stat cover on the cylinder head in that
eApply a non-permanent locking agent to the threads of
and tighten the cover bolts (2) loosely.
NOTE: Install the gasket in the correct position so that
its shape matches the mating surface on the cylinder
A. New Gasket
eSlide up the bypass pipe fully into the thermostat
and set the circlip in the groove.
NOTE: If the bypass pipe is hard to slide, wrap a piece
of clean cloth around it, and grasp it with pliers.
careful not to deform or hurt
eTighten the thermostat cover bolt (2) to 1.0 kg-m (87
ft-Ibs) of torque.
elnstall the radiator fan (Pg. 55).
elnstall the radiator
elnstall the fuel tank (Pg. 46).
AIR SUCTION VALVES
Removal (either side):
eRemove the fuel tank (Pg. 46).
eRemove the air suction valve cover bolts (6)
the cover off the air suction valve assembly.
eFor US model, remove the valve assembly taking care
not to damage the valve reeds and reed contact
If the valve assembly sticks in the cylinder head
pull it up by grasping the projection with
eFor other models, remove the aluminum plate and