How to Replace Coolant for Kawasaki KLR 650

How to Replace Coolant for Kawasaki KLR 650

Always follow the instructions in your repair manual when doing repair or maintenance work on
a motorcycle. Manuals can be found at the dealer and online.
Engine coolant will lose its ability to protect the engine and cooling system over time, so
changing the coolant should be part of every water cooled motorcycles maintenance. Kawasaki
recommends changing the coolant on the 2009 KLR 650 every 24,000 miles or 3 years, which ever
comes first. The coolant should be Ethylene Glycol based with anti-corrosion inhibitor and be
approved for use in aluminum engines.
To replace the coolant on the 2009 Kawasaki KLR 650, place the bike on a level surface and do
the replacement with the bike cold. Remove the right lower fairing, black panel in front of the
coolant reservoir, and the skid plate. Removing the skid plate with provide access to the
coolant drain plug. Remove the drain plug and radiator cap and allow all the coolant in the
engine/radiator to drain out of the bike. Remove the 4 bolts, over flow hose and cap from the
coolant reservoir. Tip the reservoir over to remove all the coolant. Now, get some fresh water
and pour it into the reservoir and radiator and flush the coolant system. Allow the fresh water
to drain out of the coolant system by tipping over the reservoir to remove the fresh water.
Secure the coolant reservoir to the bike, and reinstall the over flow hose. Reinstall the drain
plug and tighten to 78 in. lbs. Mix your Ethylene Glycol based coolant with water, so the final
mixture is 50 percent water and 50 percent coolant. Fill the radiator with the 50/50 coolant
mixture until the level of coolant is at the bottom of the radiator fill tube, and fill the
reservoir to the full line. Reinstall the radiator cap and lean the bike over from side to side
to purge any air that may be in the coolant system. Remove the radiator cap and check the
coolant level, and add coolant if it is low. Reinstall the radiator cap and start the
motorcycle and let it run for 30 seconds. Recheck the coolant level and add coolant if it is
low. Check for any coolant leaks especially around the drain plug. Reinstall the skid plate,
plastic cover for coolant reservoir, and lower right fairing.

Tools Used:
- 8mm socket, ratchet and extension
- Phillips Screwdriver
- Torque Wrench for Inch Pounds
- Plyers
- Straight Screwdriver

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