How to Change the Coolant in a 1989 Kawasaki KDX200

Shop parts for a 1989 Kawasaki KDX200 Dirt Bike.

Changing the coolant in your 1989 Kawasaki KDX200 is essential maintenance that keeps your two-stroke running strong and prevents costly engine damage. Because the KDX200 relies on liquid cooling to handle aggressive off-road use, a regular coolant change ensures the cooling system stays free from corrosion, mineral buildup, and overheating. Follow this step-by-step proprietary guide from MotoSport for a stress-free coolant service.

What You'll Need

  • Fresh, high-quality ethylene glycol-based coolant (pre-mixed or mixed to manufacturer specs)
  • Socket wrench set
  • Drain pan
  • Funnel
  • New drain bolt gasket (if the old one is damaged)
  • Rags or paper towels for cleanup
  • Safety gloves and eye protection

Step 1 – Preparation

  • Let the engine cool fully before starting. Never remove the radiator cap when the engine is hot.
  • Place your KDX200 on a stable stand and ensure there's easy access to the radiators and engine drain bolt.

Step 2 – Drain the Old Coolant

  • Remove the right radiator shroud and, if needed, the left side cover for easier access.
  • Place a drain pan under the water pump area near the bottom of the engine.
  • Carefully loosen and remove the coolant drain bolt from the lower right side of the engine (water pump cover area). Also loosen the radiator cap to allow coolant to drain freely.
  • Allow all coolant to drain completely. Replace the old gasket if damaged, and re-install the drain bolt, tightening to 15 Nm (1.5 kg-m, 11 ft-lb) torque.

Step 3 – Refill the System

  • Slowly pour the recommended coolant into the radiator up to the base of the filler neck. Pouring slowly helps release trapped air.
  • Install the radiator cap in two steps: first, turn to the initial stop; then push down and turn until fully sealed.
  • Add coolant to the reserve tank up to the FULL mark and install the cap.

Step 4 – Bleed the Cooling System

  • Locate the air bleeder bolt at the rear of the cylinder head.
  • Loosen the bleeder bolt until coolant flows out with no air bubbles – this ensures trapped air escapes from the system. Tighten the bolt securely.

Step 5 – Warm Up & Check

  • Start the engine with the radiator cap in place. Let it warm up thoroughly so the thermostat opens and coolant circulates throughout the system.
  • Shut off the bike and let it cool down completely to ambient temperature.
  • Re-check coolant level in both radiator and reserve tank. Top off as needed.

Tips & Notes Specific to the 1989 KDX200

  • The KDX200 uses a relatively small, two-row radiator system. Air pockets are more likely if coolant is filled too quickly, so always pour slowly and bleed thoroughly.
  • Damaged or old gaskets on the drain bolt are a common cause of future leaks. Always inspect and replace if needed during a coolant change.
  • The plastic reserve tank on this model can become brittle over time. Inspect it for cracks and ensure the cap seals tightly after refilling.
  • If you ride in muddy or silty environments, consider rinsing the radiator exterior with low-pressure water to prevent overheating.

Final Check

  • After the first ride, double-check the coolant level once the engine is fully cooled off. Air can sometimes burp out after the first heat cycle, requiring a top-off.
  • Always dispose of old coolant at a recycling center – never dump it in the environment.

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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.