ADJUSTING THE VALVE CLEARANCE
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- This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
- Make sure that the valve clearance is checked or adjusted while the engine is cold (at room temperature).
- While the valve clearance is checked or adjusted, make sure that the piston is positioned in the top dead center (TDC).
- Seat
- Side cover (left/right)
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Shroud (left/right)
Refer to GENERAL CHASSIS. -
Fuel tank
Refer to FUEL TANK.
- Spark plug
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Cylinder head cover
Refer to CAMSHAFT.
- Timing mark accessing screw “1”
- Crankshaft end accessing screw “2”
- O-ring
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Valve clearance
Out of specification → Regulate.
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Valve clearance (cold)
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Intake
0.12–0.19 mm (0.0047–0.0075 in) -
Exhaust
0.17–0.24 mm (0.0067–0.0094 in)
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Intake
- Check that the alignment mark “c” on the camshaft sprocket and the alignment mark “d” on the intake camshaft sprocket are aligned with the edge of the cylinder head.
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Thickness gauge
90890-03268 -
Feeler gauge set
YU-26900-9
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Thickness gauge
- Record the measured reading if the clearance is incorrect.
- Valve clearance
Refer to CAMSHAFT.
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- Place a cloth in the timing chain space to prevent adjusting pads from falling into the crankcase.
- Identity each valve lifter and adjusting pad position very carefully so that they can be reinstalled in their original place.
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Valve lapper (ø14)
90890-04101 -
Valve lapper (ø14)
YM-A8998
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Valve lapper (ø14)
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- The adjusting pad number “a” is indicated on the top of the adjusting pad.
- For the number on the originally installed adjusting pad, convert the last digit of adjusting pad number as per the below table.
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- There are 25 types of adjusting pads, ranging from 1.20 mm (0.0472 in) to 2.40 mm (0.0945 in), in increments of 0.05 mm (0.0020 in).
- The field where the number on the originally installed adjusting pad and the measured valve clearance intersect shows the adjusting pad number to replace.
Last digit of pad number
Rounded value
0, 1 or 2
0
4, 5 or 6
5
8 or 9
10
Example:
Pad number = 148
Rounded value = 150
- Do not twist adjusting pads and valve lifters forcibly during installation.
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- Apply the engine oil on the valve lifters.
- Apply molybdenum disulfide oil to the valve stem ends.
- Check that the valve lifters turn smoothly when rotated with your finger.
- Make sure that valve lifters and adjusting pads are installed in place.
- Make sure that adjusting pads are installed with their numbers facing upward.
Refer to CAMSHAFT.
VALVE CLEARANCE SHIM CHART
- Measured clearance
- Installed pad number
- Standard clearance
Example:
Valve clearance (cold) 0.12–0.19 mm (0.0047–0.0075 in)
Installed is 175.
Measured clearance 0.27 mm (0.0106 in)
Replace 175 pad with 185 pad.
Pad No. 175 = 1.75 mm (0.0689 in)
Pad No. 185 = 1.85 mm (0.0728 in)
- Measured clearance
- Installed pad number
- Standard clearance
Example:
Valve clearance (cold) 0.17–0.24 mm (0.0067–0.0094 in)
Installed is 175.
Measured clearance 0.32 mm (0.0126 in)
Replace 175 pad with 185 pad.
Pad No. 175 = 1.75 mm (0.0689 in)
Pad No. 185 = 1.85 mm (0.0728 in)
CHECKING THE ENGINE IDLING SPEED
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- Because the air pressure is lower at high altitudes, the air-fuel mixture will become richer. If the idling speed is low, turn the idle screw clockwise to increase the speed before the adjustment.
- Before adjusting the engine idling speed, make sure that the air filter element is not clogged, the engine compression is proper, and the throttle grip free play is proper.
- Adjust the engine idling speed with the starter knob pulled in completely.
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Yamaha diagnostic tool USB (US)
90890-03275
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Yamaha diagnostic tool (A/I)
90890-03273
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Yamaha diagnostic tool USB (US)
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Coolant temperature
70–80 °C (158–176 °F)
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Coolant temperature
- Digital tachometer
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Digital tachometer
90890-06760 -
Digital tachometer
YU-39951-B
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Digital tachometer
- Get the high tension cord “1” of the ignition coil pinched in the detector “a” of the digital tachometer.
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Engine idling speed
Out of specification → Regulate.
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Engine idling speed
1900–2100 r/min
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Engine idling speed
- Engine idling speed
CHECKING THE THROTTLE GRIP
- Prior to adjusting throttle grip free play, the engine idling speed should be adjusted.
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Throttle grip free play “a”
Out of specification → Regulate.
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Throttle grip free play
3.0–6.0 mm (0.12–0.24 in)
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Throttle grip free play
- Throttle grip free play
- After adjusting the throttle grip free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.
CHECKING THE SPARK PLUG
- Seat
- Side cover (left/right)
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Shroud (left/right)
Refer to GENERAL CHASSIS. -
Fuel tank “1”
Refer to FUEL TANK.
- Do not use too much force to pull the hose.
- Remove the fuel tank, turn this 180° clockwise, and put it in the frame “2” as shown.
- Holder
- Spark plug cap
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Spark plug
Refer to CAMSHAFT.
- In order not to allow the dirt accumulated around the spark plug to drop from the spark plug hole into the cylinder, clean it before removing the spark plug.
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Spark plug type
Wrong type → Replace.
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Manufacturer/model
NGK/LMAR8E-J
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Manufacturer/model
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Electrode “1”
Damage/wear → Replace the spark plug. -
Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
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Spark plug
(with a spark plug cleaner or a wire brush)
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Spark plug gap “a”
Out of specification → Adjust the spark plug gap.
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Spark plug gap
0.6–0.7 mm (0.024–0.028 in)
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Spark plug gap
- Spark plug
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Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
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Spark plug
- Before installing the spark plug, clean the spark plug and gasket surface.
- Spark plug cap
- Holder
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Fuel tank
Refer to FUEL TANK. - Shroud (left/right)
- Side cover (left/right)
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Seat
Refer to GENERAL CHASSIS.
CHECKING THE ENGINE OIL LEVEL
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Oil level
The engine oil level should be between the minimum level mark “a” and maximum level mark “b”.
Below the minimum level mark → Add the recommended engine oil to the proper level.
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- Since engine oil also lubricates the clutch, the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives.
- Do not allow foreign material to enter the crankcase.
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Recommended brand
YAMALUBE -
SAE viscosity grades
10W-40, 10W-50, 15W-40, 20W-40 or 20W-50 -
Recommended engine oil grade
API service SG type or higher, JASO standard MA
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Recommended brand
CHANGING THE ENGINE OIL
Stand the vehicle upright on a level surface.
- This model is equipped with an engine auto-stop system. The engine stops automatically if left idling for 7 minutes. If the engine stops, push the start switch to restart the engine.
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Oil filter element cover bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
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Oil filter element cover bolt
Damage → Replace.
Clogging due to dirt → Wash with kerosene.
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Oil strainer bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
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Oil strainer bolt
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Gasket
- Drain bolt
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Drain bolt
20 N·m (2.0 kgf·m, 15 lb·ft)
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Drain bolt
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Engine oil quantity
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Oil change
0.73 L (0.77 US qt, 0.64 Imp.qt) -
With oil filter removal
0.75 L (0.79 US qt, 0.66 Imp.qt) -
Quantity (disassembled)
0.95 L (1.00 US qt, 0.84 Imp.qt)
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Oil change
- Oil filler cap
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Oil level
Refer to CHECKING THE ENGINE OIL LEVEL.
- Engine oil pressure
- When the engine is started with the check bolt removed, oil will spout; therefore, always loosen it before the checkup.
- Always keep the engine idling speed during the checkup without increasing the engine speed.
- If no engine oil seeps out after one minute, immediately turn the engine off so it will not seize.
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Oil pressure check bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
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Oil pressure check bolt
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Engine guard
Refer to ENGINE REMOVAL.
ADJUSTING THE CLUTCH LEVER FREE PLAY
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Clutch lever free play “a”
Out of specification → Regulate.
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Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
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Clutch lever free play
- Clutch lever free play
- If the clutch lever free play cannot be obtained on the handlebar side, use the adjuster on the clutch cable side.
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Clutch cable locknut
4.3 N·m (0.43 kgf·m, 3.2 lb·ft)
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Clutch cable locknut
ADJUSTING THE CLUTCH LEVER POSITION
- Clutch lever position “a”
Loosen the locknut “1” and use the adjuster “2” to adjust the clutch lever position “a” as desired.
- Locknut
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Locknut (clutch lever position)
4.8 N·m (0.48 kgf·m, 3.5 lb·ft)
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Locknut (clutch lever position)
CLEANING THE AIR FILTER ELEMENT
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Sub-seat
Refer to FUEL TANK CAP. - Air filter case cover “1”
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To remove the air filter case cover:
- Raise the air filter case cover rear side while pushing the side “a” of the air intake duct from inside to unhook the ribs “b” on both sides of the air filter case cover from the air filter case “2”.
- Slide the air filter case cover to the rear of the vehicle to remove the projection “c” from the hole “d” in the air filter case.
- Air filter element guide “1”
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Air filter element “2”
(from the air filter element guide) -
Seal “3”
(from the air filter element)
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To remove the air filter element:
- Release the band “a” from the projection “b”, and then move the air filter case assembly bracket “4” in the direction of the arrow to release the projection “c”.
- Remove the air filter element and the air filter element guide as a set.
- Air filter element
- Do not use gasoline or organic (acid/alkaline) volatile oil for washing.
- Do not twist the element when squeezing the element.
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Air filter element
Damage → Replace.
- Yamaha foam air filter oil or other quality foam air filter oil
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- The element should be permeated with oil so that it is wet but not dripping.
- When replacing the element, permeate the element in oil by using the same procedure as when cleaning.
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Air filter case assembly bracket
(if removed)
Refer to THROTTLE BODY. -
Seal “1”
(to the air filter element) -
Air filter element “2”
(to the air filter element guide) - Air filter element guide “3”
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- Apply lithium-soap-based grease on the entire seal lips when installing the air filter element guide.
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To install the air filter element:
- Move the air filter case assembly bracket “4” to the rear of the vehicle.
- Set the projection “a” on the air filter element guide to the air filter case assembly bracket and insert the projection “b” on the air filter element guide to the band “c”.
- Air filter case cover “1”
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Fuel tank breather hose “2”
(to the air filter case cover)
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To install the air filter case cover:
- Insert the projection “a” on air filter case cover to the hole “b” in the air filter case “3”.
- Push the rear side of the air filter case cover to hook the ribs “c” to the air filter case.
- Insert the fuel tank breather hose end with the protector into the steering shaft hole.
- Fit the other end of the fuel tank breather hose into the projection on the fuel tank cap.
- Route the fuel tank breather hose through the guide “d”, and then fit it into the groove “e” in the air filter case cover.
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To install the air filter case cover:
- Sub-seat
CHECKING THE THROTTLE BODY JOINT
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Throttle body joint “1”
Crack/damage → Replace.
CHECKING THE FUEL LINE
- Seat
- Side cover (left/right)
-
Shroud (left/right)
Refer to GENERAL CHASSIS. -
Fuel tank
Refer to FUEL TANK.
-
Fuel hose “1”
Crack/damage → Replace.
Loose connection → Connect properly.
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Fuel tank
Refer to FUEL TANK. - Shroud (left/right)
- Side cover (left/right)
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Seat
Refer to GENERAL CHASSIS.
CHECKING THE CYLINDER HEAD BREATHER HOSE
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Breather hose “1”
Crack/damage → Replace.
Loose connection → Connect properly.
- Make sure the cylinder head breather hose is routed correctly.
CHECKING THE EXHAUST SYSTEM
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- Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.
- Do not start the engine when cleaning the exhaust system.
- Exhaust pipe 1
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Exhaust pipe 2
Refer to ENGINE REMOVAL.
- Exhaust pipe protector
- Exhaust pipe 1
- Exhaust pipe 2
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Silencer
Crack/damage → Replace.
Refer to ENGINE REMOVAL.
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Spark arrester
Carbon deposits → clean
- Spark arrester
- Pull the spark arrester out of the muffler.
- Tap the spark arrester lightly, then use a wire brush to remove any carbon deposits.
- Insert the spark arrester into the muffler and align the bolt holes.
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Spark arrester bolt
5 N·m (0.5 kgf·m, 3.7 lb·ft)
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Spark arrester bolt
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Silencer cap screw
5 N·m (0.5 kgf·m, 3.7 lb·ft)
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Silencer cap screw
- First tighten the two screws “a” located horizontally apart, and then tighten the others.
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Gasket “1”
Damage → Replace.
- Exhaust pipe 1
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Exhaust pipe 2
Refer to INSTALLING THE EXHAUST PIPE AND MUFFLER.
- Exhaust pipe protector
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Exhaust pipe protector screw
10 N·m (1.0 kgf·m, 7.4 lb·ft)
LOCTITE®
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Exhaust pipe protector screw
CHECKING THE COOLANT LEVEL
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A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows:
Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove.
- Radiator cap “1”
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Coolant level
Maximum level “a” or below → Add coolant up to the maximum level.1.
Radiator
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- Adding water instead of coolant lowers the antifreeze content. If, therefore, water is used instead of coolant, check, and if necessary, adjust the antifreeze concentration.
- Use only distilled water. However, if distilled water is not available, soft water may be used.
- Coolant level
- Before checking the coolant level, wait a few minutes until the coolant has settled.
CHECKING THE COOLING SYSTEM
- Seat
- Side cover (left/right)
-
Shroud (left/right)
Refer to GENERAL CHASSIS.
- Radiator
-
Radiator hose
Crack/damage → Replace.
Refer to RADIATOR.
- Shroud (left/right)
- Side cover (left/right)
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Seat
Refer to GENERAL CHASSIS.
CHANGING THE COOLANT
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A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows:
Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove.
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Engine guard
Refer to ENGINE REMOVAL. - Coolant drain bolt “1”
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Radiator cap
Slowly loosen the radiator cap to drain coolant.- When the radiator cap is loosened, coolant will gush out transversely; therefore, bring the container near to the outlet.
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Copper washer
- Coolant drain bolt
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Coolant drain bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
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Coolant drain bolt
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Recommended coolant
High quality ethylene glycol anti-freeze containing anti-corrosion for aluminum engine -
Radiator (including all routes)
0.93 L (0.98 US qt, 0.82 Imp.qt) -
Coolant mixing ratio
1:1 (Coolant:Water)
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Recommended coolant
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- If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.
- If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.
- If coolant is swallowed, induce vomiting and get immediate medical attention.
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- Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant.
- Use only distilled water. However, if distilled water is not available, soft water may be used.
- If coolant comes into contact with painted surfaces, immediately wash them with water.
- Do not mix different types of antifreeze.
- Radiator cap
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Coolant level
Refer to CHECKING THE COOLANT LEVEL.
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Engine guard
Refer to ENGINE REMOVAL.