Kawasaki Z400 - Service manual > Radiator

Radiator and Radiator Fan Removal

• Drain the coolant (see Want Change in the Periodic Maintenance chapter).
• Remove the middle fairings (see Middle Fairing Removal in the Frame chapter).
• Slide the damp [A] and disconnect the water hose [B].

• Slide the damp [A] and disconnect the water hose [B].
• Free the hose from the damp [C].
• Remove the radiator bolt [D]

• Remove: Radiator [A]

NOTICE

Do not touch the radi9bw cam. This could damage the radiator fins, resulting In loss of cooling efficiency.

• Remove: Radiator Fan Assy Mounting Bolts [A] Radiator Fan Assy

Radiator and Radiator Fan installation

• Installation is the reverse of removal
• Run the lead and hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).

Toque -Radiator Fan Assy Mounting Bolts: 8.4 N.m (0.86 kgf*m, 74 in*lb) L Radiator Bolt: 9.8 N-m (1.0 kgf-m, 87 In-lb)

Radiator Inspection

• Check the radiator core.

*If there are obstructions to air flow, remove them.

*If the corrugated fins [A] are deformed, carefully straighten them. .

*If the air passages of de radiator core are blocked more than 20% by un removable obstructions or irreparably deformed fins, replace the radiator with a new one.

NOTICE

When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: Keep the steam gun [A] away mom than 0.5 m (1.6 ft) [B] from the radiator core.

Hold the steam gun perpendicular [C] (not oblique [D]) to the core surface.

Run the steam gun, following the core fin direction.

Radiator Cap Inspection

• Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Coolant Reserve Tank (see Coolant Reserve Tank Removal) Radiator Cap
• Check the condition of the bottom [A] and top [B] valve seals

*If any one of them shows visible damage, replace the cap with a new one.

• Install the cap [A] on a cooling system pressure tester [B].

NOTE

Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.

• Watching the pressure gauge, pump the pressure tester to build up the pressure until the relief valve opens: the gauge needle flicks downward. Stop pumping and measure leak time at once. The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds.

*If the cap can not hold the specified pressure or if it holds , too much pressure, replace it with a new one.

Radiator Filler Neck Inspection

• Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Coolant Reserve Tank (see Coolant Reserve Tank Removal) Radiator Cap
• Check the radiator filler neck for signs of damage.
• Check the condition of the top and bottom sealing seats [A] in the filler neck. They must be smooth and dean for the radiator cap to function properly.

Water Hoses and Pipes

• Install the hoses and pipes, being careful to follow bending direction. Avoid sharp bending, kinking, flattening or twisting.
• Run the hoses (see Cable, Wire, and Hose Routing section in the Appendix chapter).
• Install the clamp [A] as near as possible to the hose end to clear the raised rib of the fitting. This will prevent the hoses from working loose.

Water Hose Inspection

• Refer to the Water Hose and Pipe Inspection in the Periodic Maintenance chapter

Water Hose and O-ring Replacement

• Refer to the Water Hose and O-ring Replacement in the Periodic Maintenance chapter.

Water Temperature  Sensor

Notice

The water temperature sensor should never be allowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it.

Water Temperature Sensor Removal/Installation

• Refer to the Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter

Water Temperature Sensor Inspection

• Refer to the Water Temperature Sensor Inspection in the Electrical System chapter.

See also: