How to Change the Coolant in a 1987 Kawasaki KLR650

Shop parts for a 1987 Kawasaki KLR650 Dirt Bike.

Routine coolant changes are a critical maintenance step that keep your 1987 Kawasaki KLR650 running reliably, preventing overheating and ensuring optimal engine temperature. Below you will find a step-by-step guide crafted for MotoSport.com visitors, with details specific to this classic dual-sport machineplus a couple of unique considerations for KLR650 owners.

Before You Begin: What Makes the 1987 KLR650 Unique

  • The 1987 model was the first year of the KLR650, renowned for its robustness but known to sometimes develop radiator and cooling system leaks with age.
  • The radiator and overflow reservoir are positioned for easy access, but the plastic reservoir is prone to age-related brittleness, so handle with care.
  • Always replace the coolant with a mixture that is safe for aluminum components, as the KLR650's cooling system includes an aluminum radiator and engine parts.
  • Check for any cracked hoses or reservoir cap wearthese are common with older bikes.

Tools & Supplies Needed

  • Phillips screwdriver
  • Socket set
  • Drain pan
  • New coolant (aluminum-safe, pre-mixed or distilled water and concentrate mixed to 50/50 ratio)
  • Funnel
  • Protective gloves & eyewear
  • Optional: hose clamp pliers, shop rags

Step-by-Step Coolant Change

  1. Let the bike cool completely. Never remove the radiator cap when hot.
  2. Remove the skid plate (if installed). Use the socket set as needed for easier access to the drain points.
  3. Access the radiator and reservoir:
    • Turn the handlebars to allow room to remove the radiator reservoir cover. Remove the two Phillips screws and take off the cover.
  4. Drain the coolant:
    • Place your drain pan under the engine.
    • Locate and remove the radiator drain bolt (bottom left of the radiator) as well as the radiator cap (right side of the bike, top of the radiator).
    • Allow the coolant to fully drain into the pan.
    • If the bike has a coolant overflow reservoir, disconnect the hoses and drain its contents as well.
  5. Flush the system:
    • Pour clean distilled water into the radiator filler neck.
    • Let it drain out the same way; repeat until clear water exits.
    • Reconnect overflow hoses and secure the reservoir if it was removed.
  6. Refill with new coolant:
    • Use a funnel to slowly fill the radiator to the base of the filler neck with your 50/50 coolant mix (about 38 fl. oz. or 1.1 liters for the KLR650's system).
    • Fill the reservoir to the recommended mark.
    • Install the radiator cap and reservoir cover. Use medium-strength threadlocker on Phillips screws if desired (to reduce loosening from vibration).
  7. Start and bleed the system:
    • Start the bike and let it run until it reaches operating temperature (watch for the temperature gauge to rise; on this model, pay attention as the early years used simple indicators).
    • Blip the throttle a few times to help evacuate trapped air. Shut off the bike and allow it to cool completely.
    • Check and top off the radiator and reservoir as needed. Air bubbles may purge themselves on the first heat cycle; repeat this check as necessary.
    • Inspect for any leaks, especially around drain bolts and hose connections.
  8. Reinstall skid plate and any removed bodywork. Wipe up spills and ensure all fasteners are snug. Clean residue from engine and radiator for easy leak inspection at the next service.

Key Reminders for 1987 KLR650 Owners

  • Change your coolant every two years or sooner if it looks dirty or rusty, especially on an older machine.
  • If your bike runs hotter than normal or loses coolant without obvious leaks, inspect the radiator cap and overflow hoses for signs of failure—this is a known issue as these parts age.
  • Use only coolants rated for aluminum engine and cooling systems to avoid internal corrosion.

This DIY guide is designed for classic KLR650 fans who keep their machines adventure-ready. The 1987 model is a legend for a reason—routine care like this will keep yours on the trail for years to come.

Related Shopping Categories

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Shop Radiator Hoses for a 1987 Kawasaki KLR650 Dirt Bike.

Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your motorcycle's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.