Kawasaki Z400 - Service manual > Coolant

Coolant Deterioration Inspection

• Remove the right middle fairing (see Middle Fairing Removal in the Frame chapter).
• Visually inspect the coolant in the reserve tank [A].

*If whish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.

*If the coolant gives off an abnormal smell, check for 6 cooling system leak. It may be caused by exhaust gas leaking into the cooling system.

Coolant Level Inspection

• Refer to the Coolant Level Inspection in the Periodic Maintenance chapter

Coolant Draining

• Refer to the Coolant Change in the Periodic Maintenance chapter

Coolant Filling

• Refer to the Coolant Change in the Periodic Maintenance chapter.

Pressure Testing

• Remove the coolant reserve tank (see Coolant Reserve Tank Removal).
• Remove the radiator cap, and install a cooling system pressure tester [A] on the filler neck

NOTE

Wet the cap sealing surfaces with water or coolant to prevent pressure leaks

• Build up pressure in the system carefully until the pressure reaches 137.3 kPa (1.40 kgf/cm2, 19.9 psi).

NOTICE

During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 137.3 kPa (1.40 kgf/cm2, 19.9 psi).

Watch the gauge for at least 6 seconds.

*If the pressure holds steady, the system is all right.

*If the pressure drops and no external source is found, check for internal leaks. Droplets in the engine oil indicate internal leakage. Check the cylinder head gasket and the water pump.

•  Remove the pressure tester, replenish the coolant, and install the radiator cap.

Cooling System Flushing

Over a period of time, the &ling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cooling system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the efficiency of the cooling system.

• Drain the ding system (see Coolant Change in the Periodic Maintenance chapter).
• Fill the cooling system   with fresh water mixed with a flushing compound

Do not use, a flushing compound which Is harmful to the aluminum engine and radiator. Carefully follow the instructions supplied by the manufacturer of the cleaning product

• Warm up the engine, and run it at normal operating temperature for about ten minutes.
• Stop the engine, and drain the coding system.
• Fill the system with fresh water.
• Warm up the engine and drain the system.
• Repeat the previous two steps OMS more.
• Fill the system with a permanent type coolant and bleed the air from the system (see Want Change in the Periodic Maintenance chapter).

Coolant Reserve Tank removal

• Remove the right middle fairing (see Middle Fairing  Removal in the Frame chapter).
• Slide the clamp and disconnect the hose [A].
• Slide the damp and disconnect the hose [B] from the radiator
• Remove:

Coolant Reserve Tank Bolts [C]

Coolant Reserve Tank [D]

• Pour the coolant into a container.

Coolant Reserve Tank installation

• Installation is the reverse of removal.
• Run the cable and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

See also: