Kawasaki KLR 650 Forum - Reply to Topic
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

Thread: Flushing the Radiator ? Reply to Thread
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  Topic Review (Newest First)
06-06-2010 05:57 PM
Scooter
radiator flush

The kawi factory service manual said to drain coolant from drain plug at water pump,close it and then drain coolant tank,reinstall tube on coolant tank after draining,and then SLOWLY pour new coolant,{ safe for aluminum motors,pre-mixed} in radiator to just below fill neck on radiator,put cap on radiator,run bike for 30 seconds to a minute,shut off open cap check level,repeat if needed.I did mine 2 months ago,it works fine.It took about half hour to do.
06-06-2010 03:47 PM
klr4evr
Quote:
Originally Posted by TomJ View Post
I need to flush out the radiator of my 05 KLR650. I read the manual that came with the bike and it said to have a qualified service person do it.

That person would be - YOU!!

Simple job as Wattman explained. Done it lots without removing rad and I used a syphon hose to drain the coolant tank.

I use Honda 50/50 premix antifreeze. No silicates or phosphates or other damaging phates. Cost a little more but it doesn't take much.
06-06-2010 10:57 AM
Watt-man
Quote:
Originally Posted by TomJ View Post
I need to flush out the radiator of my 05 KLR650. I read the manual that came with the bike and it said to have a qualified service person do it. I also have a copy of the repair manual I got. I said you have to pull the gas tank and take off a bunch of parts. Has anyone done the flush on their own? Is it really a pain? Any idea what the shops charge to do this process?
Thanks,
Tom
Tom,

Agreed the tank does not need to come off. If all you're trying to do is replace the coolant, the KLR is among the easiest vehicles on the planet to do so. Wait for the bike to cool, take off skid plate, remove radiator cap, remove drain plug. All coolant drains. You could pour in some water in the radiator (long funnel helpful) if you want to 'flush' out the system. Reinstall drain plug (70 INCH-pounds of torque). Pour in 38 fluid ounces of your favorite coolant mix. That should fill it to the top of the radiator. Reinstall radiator cap. Ride. It would be wise to drain the overflow tank (right side of bike, front of fuel tank) and refill as well.

If you believe something is plugging the radiator and it truly needs to be flushed, that's when many people might go to a shop. You can simply remove the lower radiator hose from the bottom radiator tank, hold up your garden hose to that fitting (with radiator cap off, of course - and back-flow the radiator with a garden hose.

All in all, the KLR holds less than 2 quarts of coolant, its so cheap to change that it's a good idea to do it every 2 years.
06-03-2010 01:24 PM
vatrader It can be done without pulling the tank. Be careful of wires in the region. The main ground is that area, as are a few connectors. Nudging, moving, disturbing have all contributed to no starts after messing around at the radiator area. Make note of what you touch.

I don't mean that in a discouraging way! Just be a little careful of your wiring system. What may well seem harmless at the time may be a problem later. Best to take note of what you are tinkering with.
06-03-2010 10:35 AM
TomJ I watched the videos and all seems to be pretty straight forward. Just wondering if the gas tank really has to be completely removed. It seems like I can get to everything without removing the gas tank?
06-02-2010 04:47 PM
Lockjaw
Quote:
Originally Posted by vatrader View Post
'specially now, with the advent of the computer, never before have so many underwear clad, unshaven, half drunk people been standing by to help you through your next maintenance crisis.
lol



06-02-2010 03:17 PM
vatrader

This may help...

And there really isn't much short of the transmission and lower end of the engine that the average rider can not do themselves on these bikes. All maintenance related things you can do yourself. 'Specially now, with the advent of the computer, never before have so many underwear clad, unshaven, half drunk people been standing by to help you through your next maintenance crisis.
06-02-2010 02:58 PM
Lockjaw I don't think it will work, you'll clog your toilet.

I have never done this, but someone will chime in.



06-02-2010 02:52 PM
TomJ
Flushing the Radiator ?

I need to flush out the radiator of my 05 KLR650. I read the manual that came with the bike and it said to have a qualified service person do it. I also have a copy of the repair manual I got. I said you have to pull the gas tank and take off a bunch of parts. Has anyone done the flush on their own? Is it really a pain? Any idea what the shops charge to do this process?
Thanks,
Tom

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