How to Change the Coolant in a 1996 Kawasaki KX60
Shop parts for a 1996 Kawasaki KX60 Dirt Bike.
The 1996 Kawasaki KX60 is a legendary mini motocrosser, known for its nimble handling – and top-end maintenance is essential to keep it running at its best. Replacing the coolant ensures the two-stroke engine remains well protected from overheating, corrosion, and scaling. Follow this MotoSport-exclusive guide to safely change your coolant and keep your KX60 race-ready.
What You Need
- Fresh coolant (ensure it's compatible with aluminum radiators)
- Distilled water (never use hard tap water on this small-capacity system)
- Drain pan
- 10mm and 8mm sockets – verify sizes as needed
- Phillips screwdriver
- Clean rag
- Funnel (for easier refills)
- Gloves and eye protection
Procedure for Changing Coolant
- Allow the Engine to Cool: Never open the cooling system when the bike is hot. Wait until the engine is completely cool to the touch.
- Remove the Seat & Side Panels: Use the 8mm socket to remove the seat. Remove the left side panel to access the radiator cap and reservoir, if equipped on your KX60.
- Open the Radiator Cap: Slowly open the radiator cap to relieve any internal pressure. Place a rag over the cap to avoid unexpected sprays from residual pressure.
- Locate the Coolant Drain Bolt: The drain bolt is typically found on the lower right side of the engine near the water pump cover. Place a drain pan underneath and remove the bolt with an 8mm or 10mm socket. Allow the old coolant to drain completely.
- Optional – Flush if Needed: If your coolant was dirty or old, reinstall the drain bolt and fill the system with distilled water. Reinstall the cap, run the engine briefly, shut off, then drain again for best results.
- Reinstall the Drain Bolt: Ensure the drain bolt and its sealing washer are clean and intact. Reinstall and torque snugly – do not over-tighten as the case is soft aluminum.
- Fill with Coolant: Use a funnel and slowly add coolant up to the base of the radiator filler neck. Gently rock the bike side to side to help burp air bubbles out of the system.
- Start & Bleed the System: Leave the cap off and start the bike. Let it idle for 2–3 minutes, watching for air bubbles. Top off as needed. Shut off the bike, let it cool, then re-check and top up once more before securing the cap.
- Inspect for Leaks: Check around the drain bolt and the radiator hoses for leaks before reinstalling bodywork.
- Dispose of Waste Coolant Properly: Coolant is toxic–never pour it down a drain or on the ground. Bring it to a recycling center or hazardous waste facility.
Special Notes for the KX60 Owner
- Small fluid volume: The KX60 cooling system holds far less coolant than full-size bikes, so overfilling or running low even briefly can cause overheating or engine damage.
- Check for leaks: Aging KX60s may develop coolant leaks at the water pump seal or hoses. Replace any old or cracked lines with high-quality replacements at the first sign of seepage for reliability and rider safety.
- Cap and rubber inspection: The radiator cap and its sealing gasket are essential for system pressure. If the cap shows age or doesn't feel secure, replace it to prevent boiling over or loss of coolant.
- Factory ratio and specs: Use the manufacturer-recommended coolant-to-water ratio, and always use distilled water if mixing your own coolant. Pre-mixed, motorcycle-specific coolants are recommended for both protection and convenience.
Keeping your KX60's cooling system fresh will pay off with better performance and engine longevity – making sure your next ride is all about fun, not overheating on the track.
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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.