Kawasaki Ninja Service Manual: Coolant Change

Kawasaki Ninja Service Manual / Periodic Maintenance / Periodic Maintenance Procedures / Replacement Parts / Coolant Change

WARNING

Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely.

Immediately wipe any spilled coolant from tires, frame, engine or other painted parts. Do not ingest coolant.

Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Radiator Cap [A]

Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap.

Coolant Change

Place a container under the drain bolt [A] of the water pump cover.
Drain the coolant from the radiator by removing the drain bolt.

Coolant Change

Remove: Coolant Reserve Tank Mounting Bolt [A] Cap [B]
Pour the coolant into a container.
Install the coolant reserve tank [C].
Tighten the drain bolt with new gasket.

Torque - Coolant Drain Bolt (Water Pump): 9.8 N·m (1.0 kgf·m, 87 in·lb)

Coolant Change

Fill the radiator up to the filler neck [A] with coolant, and install the radiator cap.

Coolant Change

NOTE

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

Fill the reserve tank up to the “F” level line with coolant, and install the cap (see Coolant Level Inspection).

NOTICE

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 scales accumulation in the water passages, and considerably reduces the efficiency of the cooling system.

Water and Coolant Mixture Ratio (Recommended)

Soft Water: 50%

Coolant: 50%

Freezing Point: –35°C (–31°F)

Total Amount: 2.6 L (2.7 US qt)

NOTE

Choose a suitable mixture ratio by referring to the coolant manufacturer’s directions.

Bleed the air from the cooling system as follows.

Start the engine with the radiator cap removed and run it until no more air bubbles [A] can be seen in the coolant.

Tap the radiator hoses to force any air bubbles caught inside.

Stop the engine and add coolant up to the radiator filler neck.

Install the radiator cap.
Start the engine, warm it up thoroughly until the radiator fan turns on and then stop the engine.
Check the coolant level in the reserve tank after the engine cools down.

If the coolant level is lower than the “L” level line, add coolant to the “F” level line (see Coolant Level Inspection).

Coolant Change

NOTICE

Do not add more coolant above the “F” level line.

Fuel Hose Replacement

Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). WARNINGFuel is flammable and explosive under certain conditions and can cause severe burns. Be prep ...

Radiator Hose and O-ring Replacement

Drain the coolant (see Coolant Change). Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Thermostat Housing [A] (see Thermostat Removal in the Cool ...

Other materials:

Brake Hose and Pipe Replacement
NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Brake Hose Fitting Bolt [A] Brake Hose Banjo Bolts [B] Bolt [C] Clamp ...

Cylinder Head Warp Inspection
Clean the cylinder head. Lay a straightedge across the lower surface of the cylinder head at several positions. Use a thickness gauge [A] to measure the space between the straightedge [B] and the head. Cylinder Head Warp Standard: – – – Service Limit: 0.05 mm (0.0020 in.) ...

Operating Procedures
Clean the seat area carefully. Coat the seat with machinist’s dye. Fit a 45° cutter into the holder and slide it into the valve guide. Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth. NOTICE Do not grind the seat too ...