Coolant Pressure Cap and Coolant System Testing

Inspection and Testing

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.
warning
Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
  1. Allow the engine temperature to cool for at least 30 minutes.
  2. Remove the coolant pressure cap.
  3. Check the condition of the upper and lower seals of the coolant pressure cap.
    4. Coolant Pressure Cap (cdbu.svg)

    1. Lower seal

    2. Upper seal

    3. Spring

    note
    If there is any sign of damage or deterioration replace the cap.
  4. Pressure test the cap and cooling system to the blow off pressure of 1.1 bar as described below using service tool T3880147. If the cap opens at a lower pressure or fails to open at 1.1 bar, replace the cap.
    5. note
    It is recommended to carry out coolant pressure cap and cooling system pressure tests consecutively.

Coolant Pressure Cap Test

Coolant Pressure Cap and Coolant System Testing cgwp_1

  1. Hand held pump

  2. Bayonet type connector

  3. Pressure cap test adaptor 44 mm - Adaptor B

  4. Pressure cap test adaptor 46 mm - Adaptor A

  5. Pressure cap test adaptor 44 mm - Adaptor C (Not Pictured)

  1. Select pressure cap test adaptor C - T3880453 and securely fasten to the pressure cap.
  2. Carefully connect the hand pump to the adaptor ensuring an air tight seal is maintained.
    3. Coolant Pressure Cap and Coolant System Testing cgwq_5

    1. Pressure cap

    2. Test adaptor

    3. Hand held pump

  3. Pressure test the coolant cap to the blow off pressure. If the coolant cap opens at a lower pressure, fails to open at the correct pressure or the seal leaks, replace the cap.

Coolant System Pressure Test

  1. Select the bayonet type adaptor and securely fasten to the radiator.
  2. Carefully connect the hand pump to the bayonet connector ensuring an air tight seal is maintained.
    3. Coolant System Testing (cgwr.svg)

    1. Radiator filler

    2. Bayonet type connector

    3. Hand held pump

  3. Pressurise the cooling system to the operating pressure, using the hand pump taking care not to exceed the maximum cap pressure.
  4. Hold the pressure for a minimum of 10 minutes, whilst visually inspecting the external components of the coolant system for leaks.
  5. Remove the engine oil filler cap/dipstick and check for contamination of the engine oil caused by coolant escaping into the engine sump.
    6. note
    If the engine oil is contaminated further exploratory investigation will be required.If the engine oil is contaminated rectify the cause of the problem and then renew the oil and filter.
  6. Depressurise the coolant test kit using the pressure release valve.
    7. Coolant Pressure Test - cgwr_1

    1. Radiator filler

    2. Bayonet type connector

    3. Hand held pump

    4. Pressure release valve

  7. Refit the coolant pressure cap.
  8. Fill the coolant to the maximum mark (see Coolant Replacement - Filling).