Special Tools

Description	Part Number	Qty.
COOLANT SYSTEM PRESSURE TESTER	HD-45335	1

WARNING

Do not loosen or remove pressure cap when cooling system is hot. The cooling system is under pressure and hot coolant and steam can escape from pressure cap, which could cause severe burns. Allow motorcycle to cool before servicing the cooling system. (00091c)

NOTE

Damaged filler neck cams, safety stops and sealing surfaces can cause cap to leak or affect the pressure limiting valve.

Replace filler neck if damaged. Damaged cap stop can also cause a coolant leak. Replace cap if damaged.

1.	Before troubleshooting cooling system, make sure that coolant level is at or slightly above COLD line. See Check Coolant Level in this section.
2.	NOTE Wet upper sealing surfaces before turning adapter onto tester head. See Figure 1. Clean and inspect filler neck (2), upper and lower sealing seats and overflow hose (3).
3.	Connect pressure tester to filler neck. Special Tool: COOLANT SYSTEM PRESSURE TESTER (HD-45335)
4.	NOTE When performing the coolant system pressure test, never exceed the upper limit rating of the pressure cap. Excessive pressure can rupture cooling pipes and radiator. Pump tester until pressure reaches 20 psi (138 kPa).
5.	Observe pressure gauge and proceed as indicated in Table 1.
6.	Release system pressure. Remove tester from filler neck.

Table 1. System Pressure Test

NEEDLE MOVEMENT	LEAK	ACTION
Holds steady for 2 minutes	None	None
Drops slowly	Small	Perform dye test
Drops quickly	Major	Perform visual inspection

1	Pressure test
2	Filler neck
3	Overflow hose

Figure 1. System Pressure Test