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Radiator/Oil Cooler Removal
Aside from replacing or repairing a radiator or oil cooler, you will be safest to remove them for a full system exhaust installation.
Tools:
phillips screwdriver
drip pan, 5 qaurts or larger
needle nose pliers
small sheets of plastic
rubber bands
10mm socket
6†ratchet extension
9†ratchet extension
5mm hex key socket
cup
Remove side fairings.
Do not perform any procedures on the cooling system until the motor has cooled down.
Removal
1. Remove the radiator cap by pressing down and turning one quarter turn. Turn another quarter turn and the cap will come off.
2. Using a phillips screwdriver, remove the hose clamp from the inlet hose of the radiator. Place a drip pan, 5 qaurts or larger, under the hose connection and twist the hose to loosen it from the radiator. Carefully pull the hose back until coolant starts to run from the hose.
If you are very careful, you will be able to catch all of the coolant in a drip pan. It should be transferred to a clean container and capped for storage so that it will not be contaminated.
3. Use a phillips screwdriver to remove the hose clamp from the radiator exit hose.
4. Use a needle nose pliers to release the clamp on the small radiator hose. Pull the hose off of the fitting.
5. To avoid contamination and leakage mess, place a small sheet of plastic over the open end of each hose and radiator fitting. Secure each with a rubber band. 
6. Press the tab to unlock the connector and remove it from the radiator fan.
There is a connector to remove on each side, one for each of the two radiator fans.
7. Use a 10mm socket to remove each of the two radiator/oil cooler mounting screws.
8. Using a 10mm socket and 6†extension, remove the radiator mounting bolt and washer from the top of the radiator. There are one of each on both sides.
9. Support the radiator with one hand to prevent it from falling. Use a 9†extension and 10mm socket to remove the radiator bracket mounting bolt and washer [circled in yellow].
10. Remove the radiator being careful not to bend any of the delicate fins.
11. Remove the tubes from the oil cooler using a 5mm hex key socket. Have a cup ready under the tube in case oil drips when it is disconnected.


12. Support the oil cooler with one hand. Use a 10mm socket to remove the oil cooler bracket bolt and washer under the oil cooler. Remove the oil cooler.
13. To avoid contamination, place sheets of plastic secured with rubber bands over the
open fittings on the oil cooler and the oil cooler tubes.
Installation
14. Reinstall the oil cooler using the reverse procedure of steps 11-13 above. The service manual recommends that the o-rings on the exit and return tube fittings be replaced. Apply engine oil to the o-rings before reconnecting the oil cooler hoses. Tighten the oil cooler hose bolts to 7 foot pounds.
15. Reinstall the radiator, reconnect the radiator hoses and the two fan electrical leads using the reverse procedures outlined in step 2-10 above.
16. Slowly pour the engine coolant that was removed in step 2 of this tutorial back into the radiator. Bleed the cooling system of air. (Seehttps://www.hayabusa.org/forum/maintenance-do-yourself/168998-genii-coolant-system-flush-engine-coolant-change.html, steps 7-9).
Aside from replacing or repairing a radiator or oil cooler, you will be safest to remove them for a full system exhaust installation.
Tools:
phillips screwdriver
drip pan, 5 qaurts or larger
needle nose pliers
small sheets of plastic
rubber bands
10mm socket
6†ratchet extension
9†ratchet extension
5mm hex key socket
cup
Remove side fairings.
Do not perform any procedures on the cooling system until the motor has cooled down.
Removal
1. Remove the radiator cap by pressing down and turning one quarter turn. Turn another quarter turn and the cap will come off.
2. Using a phillips screwdriver, remove the hose clamp from the inlet hose of the radiator. Place a drip pan, 5 qaurts or larger, under the hose connection and twist the hose to loosen it from the radiator. Carefully pull the hose back until coolant starts to run from the hose.
If you are very careful, you will be able to catch all of the coolant in a drip pan. It should be transferred to a clean container and capped for storage so that it will not be contaminated.
3. Use a phillips screwdriver to remove the hose clamp from the radiator exit hose.
4. Use a needle nose pliers to release the clamp on the small radiator hose. Pull the hose off of the fitting.
5. To avoid contamination and leakage mess, place a small sheet of plastic over the open end of each hose and radiator fitting. Secure each with a rubber band. 
6. Press the tab to unlock the connector and remove it from the radiator fan.
There is a connector to remove on each side, one for each of the two radiator fans.
7. Use a 10mm socket to remove each of the two radiator/oil cooler mounting screws.
8. Using a 10mm socket and 6†extension, remove the radiator mounting bolt and washer from the top of the radiator. There are one of each on both sides.
9. Support the radiator with one hand to prevent it from falling. Use a 9†extension and 10mm socket to remove the radiator bracket mounting bolt and washer [circled in yellow].
10. Remove the radiator being careful not to bend any of the delicate fins.
11. Remove the tubes from the oil cooler using a 5mm hex key socket. Have a cup ready under the tube in case oil drips when it is disconnected.


12. Support the oil cooler with one hand. Use a 10mm socket to remove the oil cooler bracket bolt and washer under the oil cooler. Remove the oil cooler.
13. To avoid contamination, place sheets of plastic secured with rubber bands over the
open fittings on the oil cooler and the oil cooler tubes.
Installation
14. Reinstall the oil cooler using the reverse procedure of steps 11-13 above. The service manual recommends that the o-rings on the exit and return tube fittings be replaced. Apply engine oil to the o-rings before reconnecting the oil cooler hoses. Tighten the oil cooler hose bolts to 7 foot pounds.
15. Reinstall the radiator, reconnect the radiator hoses and the two fan electrical leads using the reverse procedures outlined in step 2-10 above.
16. Slowly pour the engine coolant that was removed in step 2 of this tutorial back into the radiator. Bleed the cooling system of air. (Seehttps://www.hayabusa.org/forum/maintenance-do-yourself/168998-genii-coolant-system-flush-engine-coolant-change.html, steps 7-9).
