SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
SAFETY FIRST: Antifreeze is highly toxic and can kill pets and animals if drank. Do not leave coolant where animals can get to it.
CAUTION: Never open the radiator cap when the engine is hot, you could be severely burnt.
If the cooling system loses coolant, it should be pressure tested.
Radiator Pressure Testing
Remove the right radiator shroud. See the Radiator Shrouds topic for more information.
When checking the cooling system for leaks you will need a pressure tester. Remove the radiator cap and install the end of the pressure tester to the radiator. Pump the tester up until the gauge reads 17 psi – the cooling system should hold this pressure for 10 seconds. If it does not you will need to inspect the entire system for leaks.
The radiator cap test is similar to the radiator test. Install the special fitting that comes with the pressure tester kit to the radiator cap and pump up the pressure tester until it reads 18 psi- the radiator cap should hold this pressure for 6 seconds. If it does not replace the radiator cap with a new one.
Radiator Removal
Drain the coolant. See the Coolant Replacement topic for more information.
Remove the radiator cap and the overflow reservoir hose.
Unplug the cooling fan switch red/white wire. Loosen the hose clamps using a #2 Phillips head screwdriver and remove the upper and lower radiators hoses off of the radiator.
Unplug the two pin black plastic cooling fan coupler.
Remove the bolts holding the radiator to the frame using a 10 mm wrench.
Installation
Installation is essentially the reverse of removal. Tighten all fasteners securely and make sure the hose clamps are tight. Make sure to reconnect the fan switch red/white wire and the two pin black plastic coupler for the cooling fan.
Fill the radiator with coolant. See the Coolant Replacement topic for more information.
Reassemble the motorcycle. Start the engine and let it warm up completely, check for any coolant leaks.