38415-93J20 Suzuki HOLDER, PTT RELAY

1. Drain the coolant from the radiator. 2. Remove bolts (1) and grill (2). 3. Remove bolts (5) and fan guard (3). Remove bolts (6) and support bracket (4). Remove the enclosure group top panel (7).4. Remove the bolts holding the enclosure group side panels. Remove the side panels.5. Loosen the hose clamps on the upper and lower radiator hoses. Disconnect the radiator hoses from the radiator. 6. Use tooling (A) and attach a hoist to radiator (8). Remove the lower bolts holding the radiator to the base. Remove radiator (8). The weight of the radiator is 73 kg (161 lb.). The following steps are for the installation of the radiator.7. Use a hoist to install the radiator on the base. Install the bolts. Remove the hoist and tooling (A) from the radiator.8. Connect the upper and lower radiator hoses to the radiator. Tighten the hose clamps.9. Install the enclosure group side panels.10. Install the enclosure group top panel. Install the grill and the fan guard.11. Fill the radiator with coolant to the correct level. See the Maintenance Manual.Remove And Install Radiator And Radiator Guard (Prime)
1. Drain the coolant from the radiator. 2. Loosen hose clamps (4) and (5). Disconnect tube (1) from hose (6). Rotate tube (1) 180° for clearance. Remove bolts (2) from support arms (3). 3. Remove eight bolts (7) holding fan guard (8) to the radiator guard. 4. Install tool (A) and a hoist to the radiator. 5. Remove four bolts (10) that fasten the lower radiator elbow to the radiator. Separate the elbow from the radiator. Remove bolt (11) from the crankcase vent hose clamp.Remove four mounting bolts (9). Remove the radiator and radiator guard. The weight of the radiator and radiator guard is 250 Kg (550 lb.). The following steps are for the installation of the radiator and radiator guard.6. Use a hoist to put the radiator and radiator guard in position on the base. Install four mounting bolts (9). Remove the hoist and tool (A).7. Install the gasket and lower radiator elbow (12) to the radiator. Install bolts (10). Install bolt (11) and the clamp to hold the crankcase vent hose in place.8. Install bolts (7) to hold fan guard (8) in position.9. Connect tube (1) to hose (6) and tighten hose clamps (4) and (5). Install bolts (2) to secure control arms (3) to the radiator guard.10. Fill the radiator with coolant to the correct level. See the Maintenance Manual.Disassemble And Assemble Radiator
Start By:a. remove radiator and radiator guard **The radiator can be disassembled and assembled without removing the radiator and guard. 1. Remove eighteen bolts (2) and remove four plates (4). Remove four bolts, block off plate (1) and the gasket. Remove four bolts, upper radiator hose adapter (3) and the gasket. 2. Loosen four bolts (7). Disconnect tube assemblies (5) and (8). Remove four bolts (9) and remove coolant level switch if applicable. 3. Remove eleven bolts (11) and remove overflow tube (10), crankcase vent tube clamp (13) and radiator grill (12). 4. Fasten tool (A) and a hoist to top tank (14). Remove the twelve remaining bolts holding the top tank to the sides. Carefully remove the top tank from the core assemblies. 5. Remove the bolts that hold the core assemblies to plate assembly (15). Remove the plate assembly. 6. At the front of the radiator, remove the bolts and four strap assemblies (16). 7. Remove core assemblies (18) from the radiator bottom tank.8. Remove seals (17) from the radiator top tank and radiator bottom tank.9. Inspect and replace damaged parts. The following steps are for the assembly of the radiator.
The seals for the top tank are different from than the seals for the bottom tank. The top seals have a longer tab spacing than the bottom seals. Be sure the tabs engage with the holes in the tanks.
10. Apply 5P3975 Rubber Lubricant to the sealing areas of seals (17) and install them in the top and bottom tanks.11. Install core assemblies (18) into the seals in the radiator bottom tank. Install the core assemblies with the bevel edges together.12. Install the bolts and washers that hold the core assemblies to plate assembly (15). Install the bolts that hold the plate assembly to the radiator guard. Do not tighten the bolts at this time.13. Install the bolts and washers that hold the core assemblies to strap assemblies (16). Do not tighten the bolts at this time.14. Carefully lower radiator tank (14) into position on the core assemblies.15. Fasten the top tank to the sides with twelve bolts and washers. Do not tighten the bolts at this time.16. Adjust the air gap between the core assemblies at the front of the radiator to 5 to 8 mm (.197 to .315 in.).17. Tighten the bolts as the adjustment for each set of core assemblies are made.18. After the air gap for all the core assemblies has been established, tighten the remaining bolts.19. Install radiator grill, crankcase vent tube clamp and overflow tube.20. Install coolant level switch (6) and brackets.21. Install the gaskets, block off plate (1) and upper radiator hose adapter (3). Install plates (4).End By:a. install the radiator and radiator guard