Diagnostic Information And Procedures; Engine Cooling Symptom Diagnosis; Repair Instructions; Cooling Circuit Inspection - Suzuki AN400 Service Manual

Engine Cooling Symptom Diagnosis

Condition
Engine overheats
Engine over cools

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 in Section 9D
(Page9D-13)".
2) Remove the front panel. Refer to "Front Panel
Removal and Installation in Section 9D (Page9D-
14)".
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 in Section 9D (Page9D-14)".

Diagnostic Information and Procedures

Possible cause
Not enough engine coolant.
Radiator core clogged with dirt or scale. Clean.
Faulty cooling fan.
Defective cooling fan thermo-switch.
Clogged water passage.
Air trapped in the cooling circuit.
Defective water pump.
Use of incorrect engine coolant.
Defective thermostat.
Defective ECT sensor.
Defective ECM.
Defective cooling fan thermo-switch.
Extremely cold weather.
Defective thermostat.
Defective ECT sensor.
Defective ECM

Repair Instructions

B705H11606001
Engine Cooling System:
Correction / Reference Item
Add engine coolant.
Repair or replace.
Replace.
Clean.
Bleed air.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Put on radiator cover.
Replace.
Replace.
Replace.
7) Install the handlebar covers. Refer to "Handlebar
Cover Removal and Installation in Section 9D
(Page9D-13)".
1
CAUTION
!
Do not exceed the radiator cap release
pressure, or the radiator cap and
subsequently the radiator, can be damaged.
1F-6
B705H11604001
I705H1160003-02
I705H1160004-01