How to remove the radiator on a Suzuki Intruder VS1400

First, drain the oil as the oil in the sump supplies all the components on the bike and if we start removing bolts or seals that hold the oil in, we’ll get spillages. You’ll need a shallow bucket or tub, a funnel and somewhere to put your fouled oil so you can dispose of it properly.

To start the process, place a bit of wood underneath the kickstand to level the bike out to allow tub beneath the bike. Place the tub underneath the bike, ready to catch any oil.

Ideally, if it’s an option, run your engine for 10-15 minutes before draining the oil as it will loosen everything up and make the process a lot quicker.

When you’re ready, undo the sump plug (17mm nut), just so it cracks free, without taking it all the way out. Once it’s free, make sure your tub is underneath and undo it with your fingers to control the flow of oil, then remove the bolt and let it sit for an hour or so.

If you are doing a full oil change, leave the sump to drain overnight before refilling. A full oil and filter change should be completed every 6000 kilometers/3500 miles. 

Removing the radiator

There are four bolts holding the radiator in place, two on the top (10mm), two on the bottom (8mm). To start with, crack these bolts free to make sure they are not locked in place, but don’t remove them as we’ll tackle the union bolts before removing these.

There are two pipes coming out from the bottom of the radiator, we’re going to remove these with the radiator rather than taking them off.

There are two union bolts that need to be removed, one by the right side footpeg and one by the oil filter – follow the pipes down the from the radiator to find them. Put a rag down underneath as there may be a few drops of oil, the crack them free. There will be a few clips holding these pipes in place, like on the starter motor – make sure these are undone then remove the union bolts. If you need to remove any other clips, clamps or brackets, do so, remembering where they go so you can replace them during the rebuild.

Continue removing the bolts on the radiator, keeping note of which ones go where. When the radiator is free, feed the pipes through the frame and then the radiator and pipes are ready to go to the workbench.