Ahh Coolant leak!

[Arfa]

[size=1em]I appear to have small leak along seal on thermostat (bit below main coolant filler cap under tank). [/size]

[size=1em]Pretty certain it's the o-seal on this thermostat. Doesn't appears to originate from the hose or cap. (Cap was new a couple of years ago, as old wasn't holding pressure). On pressure testing the system, I get a a few small drips forming at the base of thermostat only. Anyone done this job of replacing and dismantling the thermostat? Any tips, tricks or advice?[/size]

[size=1em]Bit worried the attached hoses aren't going to like this job, as they're looking pretty old and flakey. And still we haven't sorted out any silicone hose group buys...  :eek  [/size]
[size=1em]Anyone had any joy buying random silicone sections and bends to replace some of the hoses on the FZS600? For example: [/size]
[size=1em]http://www.jsperformance.co.uk/silicone-...cone-hoses[/size]
[size=1em]Do we have any knowledge on what bends might cover what bits of the system?[/size]

[His Dudeness]

Yes it's leaking from the o ring in the middle of the thermostat. The hoses should be fine. New o ring and coolant and it should be sorted. It's an easy fix. Get the part number from the part number manual in the download section.

[bandit]

As His Dudeness said you should be able to split the housing by removing the three bolts without touching the hoses.


https://www.wemoto.com/bikes/yamaha/fzs_...ing_o_ring     

[Jules-C]

And don't overtighten the bolts because half the housing is plastic.  The official service manual has the wrong torque settings

[Arfa]

And don't overtighten the bolts because half the housing is plastic.  The official service manual has the wrong torque settings

My Haynes book quote 10Nm - sound about right?
Though TBH not sure I'll get torque wrench in there without removing all hoses and pulling lot out. 10Nm sound about hand tight anyway.

[Jules-C]

That's what official manual says Haynes probably copied.  I think I did mine about 6Nm you only want to crush o'ring slightly