How to Change the Coolant in a 1991 Kawasaki KX60
Shop parts for a 1991 Kawasaki KX60 Dirt Bike.Keeping your 1991 Kawasaki KX60 running cool and reliable starts with periodic coolant changes. This essential maintenance procedure ensures the water pump, head, and cylinder are protected from overheating and corrosion–crucial for the longevity of your two-stroke engine and its performance on the track or trail. Follow these MotoSport-exclusive steps for a thorough coolant swap plus special notes for KX60 owners.
Tools and Supplies Needed
- 8 mm socket and ratchet
- Phillips screwdriver
- Drain pan
- Funnel
- High-quality coolant (preferably non-silicate, motorcycle-specific)
- Distilled water (for flushing, optional)
- Clean shop rag
Step-by-Step Guide
- Let the bike cool down–Never open the cooling system or drain coolant while the engine is hot to avoid serious burns.
- Remove seat and side panels–Access the radiator and overflow reservoir by taking off these components using the 8 mm socket.
Locate the radiator cap, typically near the top right side. - Position the drain pan–Place it directly under the water pump cover, the typical location of the drain bolt on the KX60.
- Open the radiator cap–Remove the cap slowly to release system pressure. Some coolant may escape immediately.
- Remove the drain bolt–Identify the 8 mm bolt on the water pump cover beneath the right side of the engine. Loosen and remove it; coolant should drain freely into the pan.
Optionally, loosen the bleed screw (if equipped) to ensure full drainage. - Flush the system (optional but recommended)–Reinstall the drain bolt temporarily, fill the radiator with distilled water, run the engine briefly, shut it off, and drain again.
- Reinstall and torque the drain bolt–Check for a sealing washer. If it's damaged, replace it and torque the bolt securely (do not overtighten).
- Pour in new coolant–Use a funnel for accuracy. Fill the radiator until liquid reaches the base of the filler neck.
- Bleed trapped air–Gently rock the bike side-to-side, squeeze upper and lower hoses, and check coolant level. Add more if necessary.
- Reinstall radiator cap and panels
- Check for leaks and proper coolant level after first ride–Top off coolant if needed.
Special Notes for the 1991 KX60 Owner
- Two-stroke specific–This model lacks a thermostat; coolant cycles freely, so flush and refill intervals are important for internal corrosion prevention.
- Watch for water pump seal leaks–Older KX60 bikes may develop leaks at the water pump cover. Replace gaskets if you see seepage during or after a coolant change.
- Inspect hoses and clamps–Replace cracked hoses or worn-out clamps. Genuine parts are available via MotoSport.
- Radiator fins–Carefully clean and inspect for bent fins or debris buildup. Proper airflow is critical on air-cooled plus liquid-cooled small-displacement engines.
- Always use non-silicate motorcycle coolant–Automotive coolants may damage water pump seals and aluminum KX60 components.
Finish Strong
Routine coolant changes on your KX60 preserve peak performance and protect engine internals—a key part of keeping your classic two-stroke ready for the next ride. If you need OEM or aftermarket gaskets, hoses, or coolant, MotoSport has genuine parts for the 1991 Kawasaki KX60. Enjoy the ride.
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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.