48572-97E00 Suzuki PLUG SET, RESERVOIR

1. Drain the coolant below the level of the water temperature regulator housings. 2. Loosen the clamps and move the two hoses up off each regulator housing (1) to disconnect them from the radiator top tank.3. Use tool (A) to remove coolant filter (2) from the regulator housing on the left side of the machine. 4. Remove the gaskets and elbow (3) to disconnect the water pump from the regulator housing.5. Remove the bolts and disconnect the gasket, elbow (4) and the clip for wiring harness (5) from regulator housing (1).6. Remove the bolts and remove regulator housings (1) from each side of the engine. The following steps are for the installation of the water temperature regulator housings.7. Put the gasket, regulator and housing (1) in position on both sides of the engine and install the bolts to hold housings (1).8. Install the gaskets and elbow (3) on the right side of the machine.9. Put the gasket, elbow (4) and the clip for wiring harness (5) in position and install the bolts.10. Install coolant filter (2) on housing (1).11. Move the hoses in position and tighten the clamps to connect each regulator housing to the radiator top tank.12. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.Disassemble And Assemble Water Temperature Regulator Housings (Earlier)
Start By:a. remove water temperature regulator housings 1. Remove regulator (1) from housing (2). 2. If necessary, remove seal (3) from housing (2). 3. Remove plug (4) from the regulator housing. 4. Remove spring (5) and ball (6) from the regulator housing. 5. Use a hammer and punch to remove the pin from knob (7) and the valve. Remove knob (7) from the valve. 6. Remove bolt (8) and the washer from regulator housing (2). Pull valve (9) out of housing (2).7. Remove the O-ring seals from valve (9). The following steps are for the assembly of the water temperature regulator housings.8. If necessary, make a replacement of the coolant filter stud in housing (2). Put 9S3263 Thread Lock on the threads of the new stud that is installed in housing (2). Tighten the new stud to a torque of 60 7 N m (44 5 lb.ft.).9. Install O-ring seals on valve (9) and put clean engine oil or coolant on them. Install valve (9) in housing (2).10. Install the washer and bolt (8) to hold the valve in housing (2).11. Put knob (7) on the end of the valve and install the pin to hold the unit together.12. Install ball (6), spring (5) and plug (4) in the regulator housing. 13. Use tool group (A) to install the seals in the regulator housings. Make sure the lips of the seals are toward the inside of the housing as shown. Put clean engine oil or coolant on the lip of the seal. 14. If necessary make a replacement of ferrule (10). Install the ferrule with the orifice toward the inside of the housing.15. Install regulator (1) in the housing as shown.End By:a. install water temperature regulator housings