KLR 650 Coolant Flush

The body work (side covers, seat, tank, shrouds, skid plate) removal and installation video is here if you need it:    • KLR 650 Body Work Removal and Installation  ).

Tools you'll need:
Phillips screwdriver
8 mm socket with small ratchet
10 mm socket with medium ratchet
Torque wrench capable of 10 ft*lbs

Need a Clymer manual? Check out http://www.clymer.com/ or    / clymermanuals  

The coolant drain is a vertical bolt (8 mm) on the front right side of the engine (the water pump). There is a horizontal bolt near it which helps hold the water pump to the engine. That one won't drain it the way you want it drained... unless you want a mess.
*2008 model: the drain is in the same place, same size I think.

If you need to take off / replace the fan, those 3 bolts are 10 mm. You may need a socket extension to get to the inside fan bolt.
*2008 model: might be different. The dealership wouldn't let me take apart one of their new biikes on the showroom floor. Jerks.

If you don't have a sucky bottle (the pump thing I used in the viedo to get the coolant out of the reserve bottle), you'll need to remove the reserve bottle. There are 4 bolts, all of which are 10 mm.

Once you fill up the radiator and reserve tank, run the bike for about 30 seconds. Open the radiator cap slowly (it's pressurized). Release the pressure slowly. If the level in the radiator went down, fill it back up to the neck and replace the cap. If the reserve bottle level went down, fill that back up to the full level.

Run the bike until it gets to operating temperature. Check for leaks around the coolant drain plug, hoses, reserve bottle, and radiator (basically everywhere). If that all is leak free, rinse off the bike if you spilled any collant, and put the reserve tank cover back on.

Replace the body work (video link is up top)


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