Kawasaki J300 - Service manual > Cooling System
Coolant Level Inspection
- Check the level when the engine is cold (room or ambient temperature).
- Check the coolant level in the reserve tank [A] with the motorcycle held
perpendicular (Do not use the side stand).
If the coolant level is lower than the "LOW" level line [B], remove the reserve tank cap cover [C] by removing screw, and then remove the reserve tank cap [D] and add coolant to the "FULL" level line [E].
NOTICE For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties.
The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days.
If coolant must be added often or the reservoir tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks.
Coolant ruins painted surfaces. Immediately wash away any coolant that spills on the frame, engine, wheels or other painted parts.
Water Hose and Pipe Inspection (coolant leak, damage, installation condition)
- The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained.
- Visually inspect the hoses for signs of deterioration.
Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen.
Replace the hose if any fraying, cracks [B] or bulges [C] are noticed.
- Check that the hoses are securely connected and clamps are tightened correctly.
Torque - Water Hose Clamp Screws: 4.4 N*m (0.45 kgf*m, 39 in*lb)
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.
Front Center Cover (see Front Center Cover Removal in the Frame chapter)
Storage Box (see Storage Box 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.
- Place a container under the drain bolt [A] of the water pump cover.
- Drain the coolant from the radiator by removing the drain bolt.
- Remove the bolt [A] on the thermostat housing cover to drain the coolant completely.
Front Fairing (see Front Fairing Removal in the Frame chapter)
- Pour the coolant into a container.
- Install the coolant reserve tank [C] and tighten the bolts.
- Tighten the drain bolt with new gasket.
- When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer's directions.
NOTICE Soft or distilled water must be used with the 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%
Freezing Point: -35ºC (-31ºF)
Total Amount: 1.5 L (1.6 US qt)
- Fill the radiator up to the filler neck [A] with coolant.
- Pour in the coolant slowly so that it can expel the air from the engine and radiator.
- Check the cooling system for leaks.
- Remove the bolt [A] on the thermostat housing cover to bleed the air.
- Tap the radiator hoses to force any air bubbles caught inside.
- Tighten the bolt with a new gasket after bleeding the air.
- Fill the radiator up to the filler neck with coolant.
- Fill the reserve tank up to the "FULL" level line [A] with coolant and install the cap [B].
- 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 "LOW" level line [C], add coolant to the "FULL" level line.
NOTICE Do not add more coolant above the "FULL" level line.
Fuel Hose Inspection (fuel leak, damage, installation condition) If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hoses.
Valve Clearance Inspection NOTICE If valve clearance is left unadjusted, the wear will eventually cause the valves to remain partly open, which lowers performance, burns the valves and the valve seats, and may cause serious engine damage.