2022 Kawasaki KX450 Cooling System Owners Manual

2022 Kawasaki KX450 Cooling System

Cooling System

Water Hoses

Check the water hoses for cracks or deterioration, and the connections for looseness in accordance with the Periodic Maintenance Chart.

Radiator

Check the radiator fins for obstruction by insects or mud. Clean off any obstructions with a low-pressure stream of water.

NOTICE

• Using high-pressure water, from a car wash facility, could damage the radiator fins and impair the radiator’s effectiveness.
• Do not obstruct or deflect airflow by installing unauthorized accessories in front of the radiator.
• Interference with the cooling airflow can lead to overheating and consequent engine damage.

Coolant

The coolant absorbs excessive heat from the engine and transfers it to the air through the radiator. If the coolant level becomes low, the engine overheats and may suffer severe damage. Check the coolant level each time before riding the motorcycle, and replenish the coolant if the level is low.

WARNING
The cooling system is pressurized and can get extremely hot during normal operation and cause serious burns. To prevent burns, do not touch the radiator when it is hot. Do not attempt to open the radiator cap when hot since steam and hot coolant can forcefully erupt when the cap is even loosened slightly.

NOTE
The coolant originally filled into the cooling system contains 50% ofa permanent, ethylene-glycol-based antifreeze, has a freezing point of-35°C -31°F) and a green appearance.

Coolant Level Inspection

• Situate the motorcycle perpendicular to the ground until the radiator cap is level with the ground so that the radiator cap is located uppermost in order to exhaust the air accumulated in the radiator.
• Remove the radiator cap in two steps.
• First, turn the cap counterclockwise to the first stop and wait there for a few seconds.
• Then, push and turn the cap further in the same direction and remove it.

• • A. Radiator Cap
• Check the coolant level in the radiator. coolant should come up to the bottom of the radiator filler neck.

NOTE
Check the coolant level when the engine is cold (room or ambient temperature).

• A. Coolant Level
• B. Filler Neck

If the coolant level is low, add coolant through the radiator filler opening to the bottom of the filler neck.
Install the radiator cap.

Water and Antifreeze Mixing Ratio

L 1:1 (water:antifreeze)

Recommended Antifreeze

A permanent type of antifreeze (ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)

Coolant Total Amount

1.1 L (1.2 US qt)

Coolant Change

• The coolant should be changed to ensure long engine life, if necessary.
• Wait for the engine to cool completely.
• Situate the motorcycle perpendicular to the ground until the radiator cap is level to the ground.
• Remove the radiator cap in two steps.
• Drain the coolant from the engine and radiator in the following way.
• Place a container under the coolant drain bolt on the water pump cover and remove the drain bolt.

• • A. Coolant Drain Bolt
  • B. Water Pump Cover

NOTICE
Immediately wash away any coolant that spills on the frame, engine, or wheel.

WARNING
Coolant on tires will make them slippery and can cause loss of traction resulting in an accident and injury. Thoroughly clean any coolant that might have splashed on the tires.

• Visually inspect the old coolant.
• If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded and the system must be flushed.
• If the coolant is brown, iron or steel parts are rusting and the system must be flushed.
• Check the cooling system for damage, loose connections, and leaks.
• Install the coolant drain bolt with its new gasket at the water pump cover and apply the specified torque.

NOTE
Always replace a gasket with a new one.

• Tightening Torque
  • Coolant Drain Bolt
    • 7.0 N-m (0.71 kgfm, 62 in lb)

1. Fill the radiator up to the bottom of the radiator filler neck with coolant.
2. Lean the motorcycle slightly until the radiator filler neck is level to the ground so that the filler neck is located uppermost in order to bleed the air accumulated in the radiator.

NOTICE
Use coolant-containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufacturer. Soft or distilled water must be used with the antifreeze in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system.

NOTE
Pour in the coolant slowly so that it can expel the air from the engine and radiator.

• Loosen the air bleeder screw on the top of the left radiator until the coolant begins to flow out from the air bleeder screw hole.
  • A. Air Bleeder Screw
• Replace the O-ring of the air bleeder screw with a new one.
• Tighten the air bleeder screw to the specified torque.
• Tightening Torque

• • Air Bleeder Screw:
    • 1.6 Nm (0.16 kgf m, 14 in lb)
• Install the radiator cap.
• Check the cooling system for leaks.
• Start the engine and warm up thoroughly, then stop it.
• Check the coolant level after the engine has cooled down. The coolant should come up to the bottom of the radiator filler neck.
• If the coolant level is low, add coolant up to the bottom of the radiator filler neck.
• Install the radiator cap.
• Check the cooling system for leaks.