2022 Kawasaki KX65 Cooling System
Cooling System
Radiator Hoses
Check the radiator 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, as from a car wash facility, could damage the radiator fins and impair the radiator’s effectiveness. Do not obstruct or deflect airflow by in- stalling unauthorized accessories in front of the radiator. Interference with the cooling airflow can lead to overheating and consequent engine damage.
Coolant
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 day before riding the motorcycle, and re-plenish coolant if the level is low.
WARNING
The cooling system can get extremely hot during normal operation and cause serious burns. Do not touch the radiator when it is hot, nor open the radiator cap. Hot coolant inside will cause severe burns.
NOTE
The coolant originally filled into the cooling system contains 50% ofa permanent, ethylene-glycol -based antifreeze, has a freezing point of-35°C (-31F) and a green appearance.
Coolant Level Inspection
- Lean the motorcycle slightly to the right until the radiator cap is level to the ground, so that the radi- ator cap is located upper most 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. Radiator Breather Hose
If the coolant level is low, add coolant through the radiator filler opening to the bottom of the filler neck.
Water and Antifreeze Mixing Ratio
1:1 (water: antifreeze)
Recommended Antifreeze
A permanent type of antifreeze (ethylene glycol base plus corrosion and rust inhibitors for aluminum engines and radiators)
Coolant Total Amount
0.4L L (0.42 US qt)
Install the radiator cap.
Coolant Change
- The coolant should be changed periodically to ensure long engine life.
- Wait for the engine to cool completely.
- Learn the motorcycle slightly to the right until the radiator cap is level to the ground.
- Remove the radiator cap in two steps. (Refer to the “Coolant Level Inspection”)
- Place a container under the coolant drain plug at the water pump cover and remove the drain plug to drain the coolant from the radiator.
A. Water Pump Cover
B. Coolant Drain Plug (Water Pump)
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 inan accident and injury. any coolant that might have splashed on the tires. Thoroughly clean
- 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 plug along the new gasket at the water pump cover. Apply the specified torques.
NOTICE
Always replace the gasket with a new one, if it is damaged.
Coolant Drain Plug (Water Pump) Tightening Torque
5.2 Nm (0.53 kgfm, 46 in-lb)_
- Fill the radiator up to the bottom of the radiator fller neck with coolant.
- Lean the motorcycle slightly to the right until the radiator filler neck is level to the ground so that the filler neck is located uppermost in order to exhaust 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 (see below for 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 radiator. Bleed the air from the cooling system as follows. Loosen the air bleeder bolt on the cylinder head until the coolant begins to flow out the air bleeder bolt hole (that is, until all the remaining air has been forced out).
A. Air Bleeder Bolt
Tighten the air bleeder bolt to the specified torque.
Air Bleeder Bolt Tightening Torque
9.4 Nm (0.96 kgfm, 83 in b)
- Tap the cooling hoses to force out any air bubbles caught inside.
A. Air Bubbles
- Check the coolant level.
- 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.
- Start the engine and warm up thoroughly, then stop it.
- Check the coolant level after the engine has cooled down.
- If the coolant level is low, add coolant up to the bottom of the radiator filler neck.