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Specifications 6.1

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Specifications 6.1 HOME SPECIFICATIONS 6.1 Table 6-1. Capacities Table 6-3. Coolant Temperatures ITEM LITERS QUARTS ITEM ˚ C˚ F Engine coolant 2.4 2.54 Thermostat initially opens 85 185 Engine oil w/filter 4.3 4.5 Thermostat fully open 100 212 Engine temperature lamp 117 243 Antifreeze protection - 36.7 - 34 Table 6-2. Coolant Pressure ITEM KPA PSI Table 6-4. Fan Operation Cap lower limit 96 14 Rated cap pressure 110 16 STATUS ˚ C ˚ F Cap upper limit 124 18 On 103 217 System pressure 103 15 Off 98 208 TORQUE VALUES ITEM TORQUE NOTES Clutch diaphragm spring 90-110 in-lbs 10.2-12.4 Nm metric, page 6-14, page 6-19 retainer bolts left hand threads, apply two drops of LOCTITE Clutch hub nut 70-80 ft-lbs 94.9-108.5 Nm THREADLOCKER 262 (red) to last few threads, page 6-11 apply two drops of LOCTITE THREADLOCKER 262 Compensating sprocket bolt 155-165 ft-lbs 210.1-223.7 Nm (red) to threads, page 6-10 Primary chain tensioner fas- 15-19 ft-lbs 20.3-25.8 Nm page 6-13 teners Primary chaincase sealing fas- 25-27 ft-lbs 33.9-36.6 Nm Special sequence to tighten, page 6-5 teners Primary cover fasteners 108-120 in-lbs 12.2-13.6 Nm special sequence to tighten, page 6-3 Apply two drops of LOCTITE THREADLOCKER 262 Primary cover sleeve 15-19 ft-lbs 20.3-25.6 Nm (red) to threads, page 6-3 Transmission lockplate screws 84-108 in-lbs 9.5-12.2 Nm LOCTITE patch, use 3-5 times, page 6-22 right hand threads, initial torque only, apply several Transmission sprocket nut 100 ft-lbs 135.6 Nm drops of LOCTITE THREADLOCKER 271 (red) to last few threads. page 6-21 2007 VRSC: Cooling System 6-1 HOME COOLANT FLOW 6.2 GENERAL FLOW DESCRIPTION The VRSC engine is cooled by a an ethylene-glycol coolant See Figure 6-1. To warm the engine up quickly, the ethylene- and the lubricating engine oil. glycol coolant is re-circulated through the cylinders (13) and combustion chamber (12) in the cylinder heads. The thermo- The ethylene-glycol coolant is pressurized and circulated stat (4) blocks the passage to the radiator (11) to recirculate through the engine and a cooling radiator by an impeller type the coolant. water pump utilizing a thermostat controlled bypass. As coolant exits the pump (3), it flows through the crankcase The coolant pressure determines the coolant boiling point. and around the cylinder liners (13) removing the heat build-up The boiling point rises as the pressure increases and drops caused by the motion of the piston rings. From the cylinder as the pressure decreases. At the rated system pressure of liners (13), the coolant flows up through the cylinder head 103 kPa (15 psi), the boiling point rises to over 121˚ C and around the exhaust valves and combustion chamber (250˚ F). (12). After the coolant passes around the combustion cham- ber (12), it then flows back through the closed thermostat (4) The engine oil also cools the engine. Specifically, an oil jet into the pump (3) to repeat the cycle. This flow continues until under each piston sprays a mist of oil to lower the operating the coolant reaches 85˚ C (185˚ F) and the thermostat (4) temperature of that piston. See 3.7 OIL FLOW. opens. Once the coolant exceeds 100˚ C (212˚ F), the thermostat (4) remains open and blocks the by-pass between the entrance and exit ports of the case. An engine coolant temperature (ECT) sensor is mounted to the thermostat (4). If the temperature should exceed 117˚ C (243˚ F), the engine coolant temperature indicator on the instrument cluster will illuminate. After the coolant leaves the cylinder heads, it flows through the radiator coolant inlet pipe (5) to the radiator (11). The eth- ylene-glycol is cooled as it flows through the radiator (11) from left to right. To increase the amount of air flowing through the radiator (11), two cooling fans will turn on when the coolant tempera- ture exceeds 103˚ C (217˚ F) and will turn off when the tem- perature drops below 98˚ C (208˚ F). The coolant exits the top right of the radiator (11) and flows through the radiator outlet coolant pipe (10) to the coolant pump (3) inlet. The pressure cap (6) and radiator filler neck pressurize the coolant system. When the coolant pressure exceeds the pressure cap (6) lower limit of 96 kPa (14 psi), the lower valve opens and the excess pressure and expanded coolant flow to the overflow bottle (8) through the overflow tube (7). The over- flow bottle (8) is vented to the atmosphere through a long tube (9) which loops over the top of the radiator/oil cooler assembly and down below the coolant level. When the pres- sure drops, the pressure cap (6) vacuum valve opens to draw coolant back into the coolant inlet pipe (5) from the overflow bottle (8). 6-2 2007 VRSC: Cooling System HOME vrod_04 8 7 6 9 10 4 5 11 3 2 1 13 12 1. Red - hot coolant 2. Blue - cooled coolant 3. Water pump 4. Thermostat 5. Coolant inlet pipe 6. Pressure cap 7. Overflow tube 8. Overflow bottle 9. Overflow bottle vent tube 10. Coolant outlet pipe 11. Radiator 12. Combustion chamber coolant passages 13. Cylinder coolant passages Figure 6-1. Engine Coolant Flow (typical) (VRSCR shown) 2007 VRSC: Cooling System 6-3 HOME TROUBLESHOOTING 9548 2 1WARNING The troubleshooting section of this manual is a guide to diagnose problems. read the appropriate sections of this manual before performing any work. Improper repair and/ or maintenance could result in death or serious injury. Low Engine Temperature 1. Open thermostat. 2. Defective engine coolant sensor. 3. Defective cooling fan. 1 3 High Engine Temperature 4 1. Stuck thermostat. 2. Blocked hoses, pipes or passages. 1. Upper sealing gasket 3. Defective cooling fan. 2. Spring diaphragm 4. Faulty water pump. 3. Lower sealing gasket 4. Vacuum valve 5. Low coolant level. 6. Air in hoses, pipe or passages. Figure 6-2. Pressure Cap 7. Defective pressure cap. 8. Defective engine coolant sensor. 9546 Coolant Leaks 1 1. Damaged pressure cap gasket. 2. Faulty water pump. 3. Deteriorated O-rings on water pump. 5 4. Damaged engine gasket. 5. Leaking hose or hose connection. PRESSURE CAP 4 2 The pressure cap and radiator filler neck pressurize the cool- ant system. The pressure cap’s upper spring diaphragm gas- ket seals to the upper sealing seat in the filler neck. The lower pressure limiting valve in the pressure cap seals to the lower seat. The filler neck has an overflow tube between and upper and lower sealing seat. 3 Rising pressure compresses the spring and the lower valve opens. Excess pressure and expanded coolant flow to the overflow bottle through the overflow tube. When the pressure drops, the vacuum valve opens to draw coolant back into the radiator through the overflow tube from the overflow bottle. 1. Upper sealing seat 2. Safety stop 3. Cam 4. Overflow tube 5. Lower sealing seat Figure 6-3. Filler Neck (typical) 6-4 2007 VRSC: Cooling System HOME PRESSURE CAP TEST 9551 PART NO. SPECIALTY TOOL HD-45335 Coolant system pressure tester The pressure cap should be tested for the correct operating range every time the antifreeze is changed or any cooling system maintenance performed. 1WARNING Do not remove radiator filler cap when engine is hot. The cooling system is under pressure and hot coolant and steam can escape, which could cause severe burns. Allow engine to cool before servicing the cooling sys- tem. (00091a) 1. See Figure 6-3. Using a cloth over pressure cap, turn cap 1/4 turn counterclockwise (CCW) to safety stop (2). Let pressure escape. Press down and turn cap to pass over safety stops and remove. 2. Inspect cap for gasket deterioration and broken springs. Figure 6-4. Pressure Cap Test 3. Turn butterfly valve parallel to boss on COOLANT SYS- TEM PRESSURE TESTER (HD-45335) tester head and turn pressure cap adapter onto tester head. Turn butterfly valve perpendicular to seal tester head. NOTE To test new caps, wet the upper sealing gasket before turning onto adapter. 4. Turn pressure cap onto adapter. Rotate to safety stops. 5. See Figure 6-4. Pump handle to pressurize pressure lim- iting valve in cap. Stop pumping when pressure valve in cap opens. 6. Replace pressure cap if: a. Leaks below low limit, 96 kPa (14 psi). b. Opens above high limit, 124 kPa (18 psi). c. Pressure falls rapidly when pressurized within range. 7. Open butterfly valve and remove adaptor and cap. 2007 VRSC: Cooling System 6-5 HOME SYSTEM PRESSURE TEST 9550 PART NO. SPECIALTY TOOL HD-45335 Coolant system pressure tester The cooling system can be pressure tested to identify a leak and to verify a blown engine gasket. 1. Before troubleshooting cooling system, be sure engine coolant level is at COLD FULL mark on overflow bottle when the motorcycle is on the jiffy stand. 2. Using a cloth over pressure cap, turn cap 1/4 turn coun- terclockwise (CCW) to safety stop. Let pressure escape. Press down and turn cap to pass over safety stops and Figure 6-5. System Pressure Test (typical) remove. 3. See Figure 6-3. Clean and inspect filler neck, upper (1) and lower (5) sealing seats, overflow tube (4), and over- flow bottle. NOTE Bent filler neck cams and safety stops can cause cap to leak or affect pressure limiting valve.
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