Radiator - Removal

Warning - General - Stabilise Motorcycle

warning
Make sure the motorcycle is stabilised and adequately supported.A correctly supported motorcycle will help prevent it from falling.An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
note
Prior to disassembly of the coolant hoses, note the orientation and position of the hose clips to help ensure that they are returned to the same positions and orientation on assembly.For models fitted with the constant tension hose clips, use service tool T3880207 for their removal and installation.
warning
Do not remove the coolant pressure cap when the engine is hot. When the engine is hot, the coolant inside the radiator is hot and also under pressure. Contact with the pressurised coolant will cause scalds and skin damage.

Perform the following operations

Perform the following operations:

Seat - Remove L Series

Battery - Remove L Series

Fuel Tank - Remove L Series

Radiator Cowls - Remove LG1; LGX; LL1

Clutch Cable - Remove L Series

Radiator Remove LG1; LGX

    note
    Note the routing of the harness for the horn for installation.
  1. Disconnect the horn's two electrical connectors and detach the harness from the cooling fan cowl, noting the position of the clips and routing of the harness.
  2. Release the fixing and remove the horn.
    3. Horn Fixing (B02004)

    1. Fixing

    2. Horn

    note
    Note the routing of the harness for the cooling fan for installation.
  3. Follow the routing of the harness for the cooling fan and disconnect it from the main harness.
  4. Release the hose clip and disconnect the bypass hose from the radiator. Discard the clip.
    5. Bypass Hose LG1

    1. Hose clip

    2. Bypass hose

  5. Loosen the hose clips then detach the top and bottom hoses from the radiator.
    6. Rad Hoses LG1

    1. Hose clips

    2. Top hose

    3. Bottom hose

  6. Release the radiator lower mounting.
    7. Rad Lower Fixing LG1 (L0410_1)

    1. Fixing

    2. Radiator lower mounting

    note
    Note the position of the rubber air deflector and its retaining plate in relation to the radiator's upper mounting bolt for installation.
  7. Release the fixing securing the radiator to the frame. Slide the radiator towards the right hand side of the motorcycle to release the radiator from the bracket pin. Collect the retaining plate for the air deflector.
    8. Rad Top Mount LG1

    1. Fixing

    2. Retaining plate

    3. Bracket pin

  8. Remove the radiator.