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pretty straightforward
You will need:
-expansion tank
-funnel
-rags
-flathead screwdriver
-various size allen keys
- 8mm socket for ignition key holder bolts
-3.5 liters of coolant (little bit under a gallon, which is 3.78L)
I got the part from the dealer for $41.40 brand new (item 1)
Before I got started, I drained my coolant into a container. Save the environment and dump it at your local autozone
This gave me the opportunity to switch over to Engine Ice coolant since tracks let you use and it is antifreeze up to -25F (cost: $40 for 2 half-gallons).
Now you can put the bike on your rear stand
To get to the part, you have to:
-remove fuel tank (seat can be removed to make life easier but it can be done by not removing the seat). When you're done unbolting the tank, put down some rags atop the vertical cylinder head to soak up the residual fuel that comes out when you undo the clamps
-remove the intake trumpets (twist counterclockwise)
-remove airbox (4 bolts around perimeter) Be careful of the breather hose that connects right next to the vertical cylinder's trumpet
-unbolt ignition key switch (2bolts)
-remove both air runners that contain the air filters
-undo hose clamps (items 10 x2, 31) for hoses (items 7, 9, 29)
-remove temperature sensor on right handlebar side of the expansion tank (3 little flathead screws...careful not to lose)
Now you are ready to reassemble
I just reused my filler neck and cap(items 2, 3, 5) for the new part
Important:
-take the rubber bump stop (item 34) and shave off bout 1/4" of material with an exacto knife or a box cutter or whatever you feel like. This will give your new tank more room to actually expand when it gets hot as is intended in expansion tanks, thus fixing the design problem of this layout.
Even more important.... half a BEER, cuz ur gonna have to refill your coolant with a short ride
![]()
while you admire how far you've gotten
-Make sure the hoses are reconnected the right way (item 7 and item 9 in particular) or else the airbox will squish them and it will hard to put the airbox back in.
How do I know?......experience
Coolant refill part
-Start your engine
-While the engine idles, fill your coolant through the expansion tank slowly. Keep track of how much it s taking. Lean your bike side to side to get rid of air bubbles. Squishing the coolant hoses (28, 26, 29, 33, etc) while the bike idles helps also
-When you get to the MAX line on the expansion tank, put the cap back on and position the tank in place but don t bolt it in yet.
-Go out for a little ride, about 5-10 miles or so until the bike is kinda hot.
- Rotate your tank out of the way and get a towel and SLOWLY remove the filler cap of the expansion tank. When it starts to his, go slower and let it hiss off and take the cap out.
-Fill back up to the MAX line. by keeping your bike on the ground and standing it upright (not on the stand). If you have too much, use a turkey baster to remove the excess coolant.
-Bolt your tank back up.
more beer
question? comments?
![]()
Consult picture at end of post for items
You will need:
-expansion tank
-funnel
-rags
-flathead screwdriver
-various size allen keys
- 8mm socket for ignition key holder bolts
-3.5 liters of coolant (little bit under a gallon, which is 3.78L)
I got the part from the dealer for $41.40 brand new (item 1)
Before I got started, I drained my coolant into a container. Save the environment and dump it at your local autozone
This gave me the opportunity to switch over to Engine Ice coolant since tracks let you use and it is antifreeze up to -25F (cost: $40 for 2 half-gallons).
Now you can put the bike on your rear stand
To get to the part, you have to:
-remove fuel tank (seat can be removed to make life easier but it can be done by not removing the seat). When you're done unbolting the tank, put down some rags atop the vertical cylinder head to soak up the residual fuel that comes out when you undo the clamps
-remove the intake trumpets (twist counterclockwise)
-remove airbox (4 bolts around perimeter) Be careful of the breather hose that connects right next to the vertical cylinder's trumpet
-unbolt ignition key switch (2bolts)
-remove both air runners that contain the air filters
-undo hose clamps (items 10 x2, 31) for hoses (items 7, 9, 29)
-remove temperature sensor on right handlebar side of the expansion tank (3 little flathead screws...careful not to lose)
Now you are ready to reassemble
I just reused my filler neck and cap(items 2, 3, 5) for the new part
Important:
-take the rubber bump stop (item 34) and shave off bout 1/4" of material with an exacto knife or a box cutter or whatever you feel like. This will give your new tank more room to actually expand when it gets hot as is intended in expansion tanks, thus fixing the design problem of this layout.
Even more important.... half a BEER, cuz ur gonna have to refill your coolant with a short ride
-Make sure the hoses are reconnected the right way (item 7 and item 9 in particular) or else the airbox will squish them and it will hard to put the airbox back in.
How do I know?......experience
Coolant refill part
-Start your engine
-While the engine idles, fill your coolant through the expansion tank slowly. Keep track of how much it s taking. Lean your bike side to side to get rid of air bubbles. Squishing the coolant hoses (28, 26, 29, 33, etc) while the bike idles helps also
-When you get to the MAX line on the expansion tank, put the cap back on and position the tank in place but don t bolt it in yet.
-Go out for a little ride, about 5-10 miles or so until the bike is kinda hot.
- Rotate your tank out of the way and get a towel and SLOWLY remove the filler cap of the expansion tank. When it starts to his, go slower and let it hiss off and take the cap out.
-Fill back up to the MAX line. by keeping your bike on the ground and standing it upright (not on the stand). If you have too much, use a turkey baster to remove the excess coolant.
-Bolt your tank back up.
more beer
question? comments?
