Filler neck hose clamps (A), cover

Bolts (B), housing hose clamps (C),

Mounting bolt (D)

A Slacken the clamps (arrowed) and detach the hoses

B Thermostat housing mounting bolt (arrowed)

3 The thermostat is located in the thermostat housing, which on J and К models is mounted to the right-hand frame spar, and on L, N and R models is mounted on the crankcase above the gearbox.

4 On J and К models, to remove the thermostat, slacken the clamp securing the overflow hose to the filler neck and detach the hose (see illustration). Unscrew the two bolts securing the cover and separate it from the housing. Withdraw the thermostat, noting how it fits. Discard the cover O-ring as a new one must be used. To remove the thermostat housing, disconnect the temperature sender wiring connector (see illustration 5.2a). Slacken the clamps securing the hoses to the filler neck and the thermostat housing and detach the hoses, noting which fits where. Unscrew the bolt securing the housing to the frame and remove the housing,

5 On L, N and R models, the thermostat housing must be removed to access the thermostat. Disconnect the temperature sender wiring connector (see illustration 5.2b). Slacken the clamps securing the hoses to the thermostat housing and detach the hoses, noting which fits where (see illustration). Unscrew the bolt securing the housing to the engine, accessing it from the left-hand side of the bike, and remove the housing (see illustration). To remove the thermostat, unscrew the two bolts securing the cover and separate it from the housing (see illustration). Withdraw the thermostat,

noting how It fits. Discard the cover O-ring as a new one must be used.

Check

6 Examine the thermostat visually before carrying out the test. If it remains in the open position at room temperature, it should be renewed.

7 Suspend the thermostat by a piece of wire in a container of cold water. Place a thermometer in the water so that the bulb is close to the thermostat (see illustration). Heat the water, noting the temperature when the thermostat opens, and compare the result with the specifications given at the beginning of the Chapter. Also check the amount the valve opens after it has been heated at 95°C for a few minutes and compare the

6.5c Unscrew the bolts (arrowed), lift off the cover and remove the thermostat

measurement to the specifications. If the readings obtained differ from those given, the thermostat is faulty and must be renewed.

8 In the event of thermostat failure, as an
emergency measure only, it can be removed
and the machine used without it. Note: Take
care when starting the engine from cold as it
will take much longer than usual to warm up.
Ensure that a new unit is installed as soon as
possible.

Installation

6.7 Thermostat testing set-up

9 Installation is the reverse of removal. Use a
new O-ring (see illustration). Make sure the
thermostat seats correctly (see illustration).
On L, N and R models, make sure the locating
hole in the hosing fits onto the locating pin
(see illustration). Tighten the bolts and the

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