Suzuki SV1000 2003-2005 Service Manual 5 Cooling and Lubrication System

COOLING AND LUBRICATION

COOLING AND LUBRICATION SYSTEM

CONTENTS

SYSTEM 5-1

,of

ENGINE COOLANT
COOLING CIRCUIT

INSPECTION

RADIATOR

RADIATOR RESERVOIR TANK

RADIATOR CAP

WA TER HOSE

INSPECTION

COOLING FAN

REMOVAL AND INSTALLATION
INSPECTION

COOLING FAN THERMO-SWITCH

REMOVAL
INSPECTION
INSTALLATION

ENGINE COOLANT TEMPERATURE SENSOR

REMOVAL
INSPECTION
INS TA LA TION

THERMOSTAT

REMOVAL
INSPECTION
INSTALLATION

WATER PUMP

REMOVAL AND DISASSEMBLY
INSPECTION AND CLEANING
REASSEMBLY AND INSTALLATION

LUBRICATION SYSTEM

OIL PRESSURE
OIL FILTER
OIL PRESSURE REGULATOR
OIL STRAINER
OIL JET
OIL PUMP

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REMOVAL
INSTALLATION
INSPECTION AND CLEANING

REMOVAL AND INSTALLATION

INSPECTION

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5- 3
5- 4
5- 4
5- 5
5- 5
5- 6
5- 6
5- 7
5- 7
5- 7
5- 7
5- 7
5- 7
5- 8
5- 8
5- 8

5- 9
5- 9
5- 9
5- 9

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5-10
5-10
5-10
5-11

5-12
5-12
5-12
5-13
5-14
5-14
5-15
5-16
5-19
5-19
5-19
5-19
5-19
5-19
5-19

5

COOLING AND LUBRICATION SYSTEM

5-

2

COOLING AND LUBRICATION SYSTEM

CONTENTS

OIL PRESSURE SWITCH

OIL COOLER

REMOVAL
INSTALLATION

INSPECTION AND CLEANING
ENGINE LUBRICATION FLOW CHART
ENGINE LUBRICATION CIRCUIT

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5-19
5-20
5-20
5-21
5-21
5-22
5-23

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5-

COOLING AND LUBRICATION SYSTEM

3

ENGINE COOLANT

At the time of manufacture, the cooling system is filled with a

:50 mixture of distilled water and ethylene glycol anti-freeze

50
This 50

and excellent heat protection, and will protect the cooling system
from freezing at temperatures above -31 °C (-24 °F)

If the motorcycle is to be exposed to temperatures below -31 °C
(-24 °F), this mixing ratio should be increased up to 55 % or

60 % according to the figure

CAUTION

50 % engine coolant including reservoir tank capacity

:50 mixture will provide the optimum corrosion protection

.

.

•

Use a high quality ethylene glycol base anti-freeze,
mixed with distilled water
base anti-freeze and different brands of anti-freeze

•

Do not rut in more than 60%anti-freeze or less than
50 %

. (Refer to the right figure

•

Do not use a radiator anti-leak additive

Anti-freeze

Water

. Do not mix an alcohol

.)

.

1 100 ml (2
1 100 ml (2

.3/1

.9 US/Imp-pt)

.3/1

.9 US/Imp

.pt)

.

.

Anti-freeze

density

50%
55%
60%

(F) (C)

32

-10

14

-20

-4

C

0

Q
O)

C
N

a)

a)

U-

Fig

-30

-22

-40 -40

-58 -50

-60

-76

-70

-94

.1 Engine coolant density-freezing

point curve

Freezing point

-31 °C (-24 °F)

-40 °C (-40 °F)

-55 °C (-67 °F)

0

40

20

60

80

Density (%)

100

04

(°F) (°C)
302 150

284 140

c
Q

266 130

0)
248 120

:0

m

230 110

212 100

0 10

.2 Engine coolant density-boiling

Fig

point curve

WARNING

A

You can be injured by scalding fluid or steam if you open the radiator cap when the engine is

•

. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by

hot

turning it a quarter turn to allow pressure to escape and then turn the cap all the way off

•

The engine must be cool before servicing the cooling system

•

Coolant is farmful

If the comes in contact with skin or eyes, flush with water

•

If swallowed accidentally, induce vomiting and call physician immediately

•

•

Keep it away from children

;

.

.

.

20 30 40

Density (%)

.

(kgf/cm2)

50 60

1

.5

0

.9

a)

0

.5

0)

Z3

0

(7

.

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5-4COOLING AND LUBRICATION SYSTEM

COOLING CIRCUIT

RESERVOIR TANK

RADIATOR

NO

. 1 CYLINDER HEAD

. 1 CYLINDER

NO

THERMOSTAT

NO

. 2 CYLINDER

NO

. 2 CYLINDER HEAD

WATER PUMP

INSPECTION

Before removing the radiator and draining engine coolant,

inspect the cooling circuit for tightness

•

Remove the body cowling

•

Remove the radiator cap ®

Connect the tester 02 to the filler

•

A WARNING

Do not remove the radiator cap when the engine is
hot

.

•

Give a pressure of about 110 kPa (1
see if the system holds this pressure for 10 seconds

If the pressure should fall during this 10-second interval, it

•

means that there is a leaking point in the system
case, inspect the entire system and replace the leaking com-

ponent or part

.

. (=6-6)

.

.

.

.1 kgf/cm

2

,15.6 psi) and

.

. In such a

A WARNING

When removing the radiator cap tester, put a rag on
the filler to prevent spouting of engine coolant

CAUTION

Do not allow the pressure to exceed the radiator cap
release pressure, or the radiator can be damaged

.

.

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COOLING AND LUBRICATION SYSTEM5-5

I

RADIATOR

40

REMOVAL

•

Drain engine coolant.(C-.
Disconnect the radiator hoses from the radiator

•

Disconnect the siphon hose from the radiator

•

7-2-19)

.

.

Disconnect the horn lead wire coupler

•

Remove the radiator by removing its mounting bolts

•

Disconnect the cooling fan motor lead wire coupler 10

•

.

.

.

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5-6COOLING AND LUBRICATION SYSTEM

•

Remove the radiator side covers

•

Remove the cooling fan thermo-switch

•

Remove the cooling fan and horn

INSTALLATION

•

Install the cooling fan and horn

Cooling fan/horn mounting bolt

•

•

Install a new 0-ring and tighten the cooling fan thermo-switch

02

to the specified torque

•

Cooling fan thermo-switch

•

Connect the cooling fan thermo-switch coupler

•

Install the radiator side covers

•

Install the radiator in the reverse order of removal

•

Pour engine coolant.(F-

•

Bleed air from the cooling circuit

.

72-19)

.

.

.

:

8 N

: 17 N

.m (1

.

. (CI2-20)

02

.

.m (0

.8 kgf-m, 6

.7 kgf-m, 12

.0 lb-ft)

.5 lb-ft)

.

.

INSPECTION AND CLEANING

•

Road dirt or trash stuck to the fins must be removed

•

Use of compressed air is recommended for this cleaning

•

Fins bent down or dented can be repaired by straightening

them with the blade of a small screwdriver

.

.

.

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COOLING AND LUBRICATION SYSTEM5-7

RADIATOR RESERVOIR TANK
REMOVAL AND INSTAL

•

Lift and support the fuel tank

•

Disconnect the siphon hose from the radiator

•

Remove the reservoir tank by removing its mounting bolt

•

Drain engine coolant

•

Install the reservoir tank in the reverse order of removal

•

Fill the reservoir tank to the upper level

.

LA

TION

.(rr4-65)

.

.

.

.

RADIATOR CAP
INSPECTION

•

Fit the cap 90 to the radiator cap tester

•

Build up pressure slowly by operating the tester

that the pressure build-up stops at 95

kgf/cm2,13.5-17
still, the cap is capable of holding that pressure for at least 10
seconds

•

Replace the cap if it is found not to satisfy either of these two
requirements

.

.8 psi) and that, with the tester held stand-

.

(2)

.

-

125 kPa (0

. Make sure

.95

-1.25

Radiator cap valve opening pressure

Standard

95-

:
125 kPa (0

.95-1

.25 kgf/cm

2 ,

13.5-17.8 psi)

WATER HOSE

INSPECTION

•

Any water hose found in a cracked condition or flattened or
water leaked must be replaced

•

Any leakage from the connecting section should be corrected
by proper tightening

.

.