Kawasaki Z1000SX - Service manual > Thermostat

Thermostat Removal

• Remove:
  Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter)
  Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter)
  Harness Holder Clamp [A]
  Water Hose Clamp [B]
  Water Hose [C]
  Water Pipe Bolts [D]
  Water Pipe [E]

• Loosen the water hose clamp screw [A].
• Clear the starter motor cable from the holder [B].

• Remove:
  Thermostat Housing Bolts [A]
  Thermostat Housing Cover [B]
  Thermostat

Thermostat Installation

• Install the thermostat [A] in the housing so that the air bleeder hole [B] is on top.

• Replace the O-ring [A] with a new one.
• Apply grease to the O-ring, and install it.
• Install the thermostat housing cover.

NOTE

• Note that the thermostat does not move at the place when installing the thermostat housing cover.

• Tighten:
  Torque - Thermostat Housing Bolts: 5.9 N*m (0.60 kgf*m, 52 in*lb)
• Apply a non-parmanent locking agent to the threads of the water pipe bolt.
• Tighten:
  Torque -
   Water Pipe Bolt: 12 N*m (1.2 kgf*m, 106 in*lb)
   Radiator (Water) Hose Clamp Screws: 2.9 N*m (0.30 kgf*m, 26 in*lb)
• Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
• Fill the radiator with coolant (see Coolant Change in the Periodic Maintenance chapter).

Thermostat Inspection

• Remove the thermostat (see Thermostat Removal), and inspect the thermostat valve [A] at room temperature.

  If the valve is open, replace the thermostat with a new one.

• To check valve opening temperature, suspend the thermostat [A] in a container of water and raise the temperature of the water.
  • The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth.

    It must not touch the container, either.

If the measurement is out of the specified range, replace the thermostat with a new one.

Thermostat Valve Opening Temperature 58 - 62ºC (136 - 144ºF)

Hose and Pipes

Hose Installation

• 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.
  • The clamp screws should be positioned correctly to prevent the clamps from contacting the other parts.

Torque - Radiator (Water) Hose Clamp Screws: 2.9 N*m (0.30 kgf*m, 26 in*lb)

Hose Inspection

• Refer to the Radiator Hose Damage and Installation Condition Inspection 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: