How to Change the Coolant in a 1997 Kawasaki KDX220

Shop parts for a 1997 Kawasaki KDX220 Dirt Bike.

Routine coolant changes keep your 1997 Kawasaki KDX220 running cool and performing at its best, especially important for aggressive trail rides or tight enduro work where overheating can threaten your engine. The KDX220's robust two-stroke engine uses a liquid cooling system that's effective but benefits from careful maintenance. Let’s walk you through the MotoSport proprietary step-by-step guide for a coolant swap, including KDX220-owner must-knows.

What Makes the 1997 KDX220 Special?

The KDX220 builds on the legendary KDX200’s chassis but features a larger 220cc engine for more low-end torque—a favorite among woods riders. This model does not use a thermostat, so air bleeding is critical to prevent hot spots and coolant circulation problems. Frequent tip-overs or riding in rough terrain increases the risk of trapped air, making proper burping essential.

Tools & Supplies You’ll Need

  • Fresh coolant suitable for aluminum engines (premixed or mix with distilled water as specified)
  • Drain pan
  • 10mm or 12mm wrench (for drain bolt on water pump cover)
  • Phillips screwdriver (for radiator cap and possible shrouds)
  • Rags
  • Funnel
  • Latex gloves (optional, but helps with cleanup)

Step 1: Prepare for Coolant Draining

  • Let the engine cool completely to avoid burns.
  • Set the dirt bike securely on a stand or level surface.
  • Remove the radiator cap to break any system vacuum.

Step 2: Drain the Old Coolant

  • Place the drain pan under the water pump cover (right side of engine).
  • Locate the coolant drain bolt at the base of the water pump.
  • Use the wrench to remove the bolt and let coolant flow out entirely.
  • For a more complete drain, loosen the lower radiator hose clamp and disconnect the hose at the pump cover.

Step 3: Flush (Optional but Recommended)

  • With the drain bolt and hoses off, flush the radiators and engine with distilled water for a thorough clean.
  • Reattach the hoses, tighten the clamps, and install the drain bolt (use a new washer if the old one is damaged).

Step 4: Refill with Fresh Coolant

  • Slowly pour coolant into the radiator filler neck, allowing air bubbles to escape. Take your time—rushing introduces air pockets.
  • Fill the radiator to just below the filler neck base, not overflowing it.
  • If equipped, fill the overflow reservoir to the "Full" mark.

Step 5: Burp the Cooling System

  • Leave the radiator cap off.
  • Start the engine and let it idle. Lean the bike slightly side-to-side (carefully), squeezing the hoses by hand to help trapped air rise.
  • As the engine heats, watch for air bubbles emerging from the radiator filler neck. Add coolant as the level drops.
  • Once bubbling subsides and the fluid remains steady, reinstall the radiator cap securely.

Step 6: Recheck Coolant Levels

  • Run the bike up to operating temperature, then shut it off and allow it to cool completely.
  • Check the radiator and reservoir level once more—top up if necessary.

KDX220 Owner Tips

  • Frequent "off-balance" moments can introduce air, requiring more frequent burping than other bikes.
  • For heavy use, consider replacing radiator hoses and radiator cap if age or wear is present for maximum reliability.
  • If replacing the water pump shaft or disassembling the pump, always use molybdenum disulfide grease to prevent premature seal wear and ensure correct seal installation direction.
  • Overfilling the system can cause overflow & make a mess—always leave a small air gap in the radiator.

Disposal & Safety

Never pour old coolant down drains or onto the ground. Coolant is toxic to humans and animals. Collect it in a sealed container and dispose of at your local recycling center or hazardous waste facility.

When to Change Coolant Next?

Change coolant at least once every two years, or more often if you ride hard, overheat, or notice contamination in the system. Fresh coolant guards your KDX220’s engine and extends the life of seals, hoses, and pump components.

Stay safe and enjoy your 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.