09250-08016 Suzuki CAP

1. Remove bolts (1). Remove cover (2), gasket, valve assembly, and plate.2. Remove bolts (3). Remove cap assembly (4), and remove the pipe assembly. 3. Remove two bolts and link brackets (5). Remove remainder of bolts (6) that hold two shields (7) to the plate assembly. Remove two shields (7). 4. Remove bolts (8). Remove elbow and adapter (9). Remove the gasket. 5. Remove remainder of bolts (10) that hold two shields (11) to the plate assembly. Remove two shields (11). 6. Install tooling (A) to the radiator. 7. Remove two bolts (12) on each side at the bottom of the radiator. Remove two caps (13) and remainder of the two mount assemblies. 8. Remove two bolts (14) and cap (15) on each side at the top of the radiator. Remove radiator (16) from the radiator guard. The weight of the radiator is 77 Kg (170 lbs.). 9. Disconnect hydraulic oil line (17) from the core assembly (18) at the bottom of the radiator. 10. Disconnect hydraulic oil line (19) from core assembly (18) and bracket (20) at top of the radiator. 11. Remove bolts (21) that fasten top tank assembly (26) to channel assembly (22) on each side of the radiator.12. Remove top tank assembly (26) from the radiator cores. The weight of the top tank assembly is 24 Kg (54 lb.).13. Remove the rubber seals from the bottom of the top tank assembly. Some of the seals may stay on the radiator cores. Remove them also. If all of the radiator cores need to be removed, remove bolt (23) from each side of the radiator. All of the radiator cores can be removed from the bottom tank assembly as an assembly.14. Remove two bolts (25) from bracket (24), one at the rear not shown, for each radiator core that is to be removed.15. Remove the radiator core from the bottom tank assembly. 16. Remove rubber seal (27) from the bottom tank assembly.Install Radiator (Later)
1. Lubricate all rubber seals (27) at the bottom and top of the radiator cores with liquid soap just prior to assembly. 2. Install the radiator cores with rubber seals on the bottom tank assembly.3. Put top tank assembly (26) with rubber seals on the top of the radiator core assemblies (18). Install bolts (21) that fasten top tank assembly (26) to channel assembly (22) on each side of the radiator.4. Install bolts (25) on brackets (24). Install bolt (23) on each side of the radiator, if it was removed. 5. Before tightening bolts (25), adjust gap (X), at the front of the radiator, to 6.5 mm (.25 in.). The cores must not contact each other after assembly. 6. Connect hydraulic oil line (19) to core assembly (18) and bracket (20) at the top of the radiator. 7. Connect hydraulic oil line (17) to the core assembly (18) at the bottom of the radiator. 8. Install tooling (A) to the radiator. Put radiator (16) in position in the radiator guard with a hoist. Install cap (15) and bolts (14) on each side at the top of the radiator. 9. Install mount assemblies and caps (13) on each side at the bottom of the radiator. Install bolts (12) that hold the caps. Remove tooling (A) from the radiator. 10. Install two shields (11) to the plate assembly at the bottom of the radiator. 11. Replace the gasket if necessary, and install elbow and adapter (9) with bolts (8). 12. Install two shields (7) at the top of the radiator with bolts (6). Install two link brackets (5). (Link brackets are for installation of radiator and guard). 13. Install pipe assembly and cap assembly (4) with bolts (3).14. Install plate, valve assembly, a new gasket if necessary, and cover (2) with bolts (1).End By:a. install radiator and guard (later)