2001 kawasaki VN 1500 Vulcan Classic Tourer - Fi Logo
Posted on May 19, 2009

Drained radiator to change coolant. How do you refill radiator when reservoir only takes about 3/4 of a quart?

2001 Kawasaki Nomad; Drained radiator to change coolant. How do you refill when reservoir only takes about 3/4 quart?

2 Answers

Chris L

Level 1:

An expert who has achieved level 1.

New Friend:

An expert that has 1 follower.

Mayor:

An expert whose answer got voted for 2 times.

  • Contributor 1 Answer
  • Posted on May 29, 2012
Chris L
Contributor
Level 1:

An expert who has achieved level 1.

New Friend:

An expert that has 1 follower.

Mayor:

An expert whose answer got voted for 2 times.

Joined: May 29, 2012
Answers
1
Questions
0
Helped
4876
Points
1

So what's the deal with this eh? We know we're driving liquid cooled bikes, we know the coolant should be replaced every year or two to prevent corrosion (and, coincidentally protect the system from extreme cold) but when was the last time you changed coolant? Well then it's about time right? Below are instructions straight from the Kawasaki Maintenance manual. One caution. A helper is always handy when removing the gas tank. One person to hold the tank, the other to remove hoses (especially in the case of the FI).
And what coolant should you use? Kawasaki recommends a permanent type antifreeze (a mix of soft water and ethylene glycol plus corrosion and rust in inhibitors) for aluminum engines and radiators (silicate free). If you're looking for other options check out this other Fixit page. For whatever it's worth I use Honda Pro Coolant. It is pre-mixed with de-ionized water and comes in a blue quart bottle. Cost will be around $4 a quart but you're going to know it's good for your bike.
Total amount needed for a complete refill is 2.3 liters or 2.43 quarts. You'll use most of the leftover half quart to refill your coolant overflow tank.
So lets get to it!

1. Place a container under the radiator drain bolt (bottom of radiator) and remove bolt. Careful, there is a rubber washer that can fall off the bolt. Lose that and your radiator will be drip, drip, dripping away until you find a replacement.
2. Remove fan controller unit (for cleaning) & reinstall. (dealers tend to skip this since it can be a little time consuming to get to)
3. Remove or pull back gas tank (Gadget note: removal is much simpler on the carbed bikes so you might as well get the tank out of your way. FI riders may want to remove the vent hose(s) from the rear of the tank then just move the tank rearward about three inches. This will give you access to the radiator cap)
4. Remove radiator cap
5. Remove water pump drain bolt (lower left corner) so any coolant remaining in engine can dribble out. It'll be less messy if you can fashion a funnel from something to guide the coolant to your drain container.
6. Remove right side cover and reserve tank bolts then reserve tank. Remove hose from container and drain coolant. Clean tank thoroughly and reinstall. (a bottle brush helps with this cleaning)
6a An optional step here. Using distilled water and white vinegar create a 50/50 mix. Put the drain plugs back in your radiator & water pump then pour the mixture into the radiator cap opening. Put the cap on and run engine until warm. Let cool and drain the mixture. Pour clear (distilled) water through the system allowing it to drain from the radiator and pump exits flushing all the vinegar/water mixture out.
7. Mix your coolant (unless you purchased pre-mix). Make sure all the drains you've loosened are tight. Pour coolant slowly into filler neck. Fill overflow tank to the 'full' mark.

___________________
At this point there are two approved methods for re-filling the radiator. The first uses the air bleeder bolt which is forward of the radiator cap (looks like a brake bleeder). The other is probably the method you've used with your car, the 'engine running' method. Either way you're likely to spill some coolant so do this someplace where you can get a hose on the spill and rinse away easily.
Method 1, using the air bleeder bolt:

1. Install radiator cap
2. Fill reserve tank to the "full" level with coolant and put the cap on
3. Bleed air from the system using the air bleeder bolt in the casting below radiator cap. (torque on that bolt is 69 in lbs)


Method 2, running the engine and letting the air out through the cap opening:


1. Start engine (radiator cap off) and run until no more air bubbles can be seen. Tap radiator hoses to force any remaining air bubbles to the top. Stop engine, add coolant to top of filler neck. Install cap
2. Remove reserve tank cap again and fill tank to the 'full' level. reinstall cap.
3. Install side cover

Finally, Ride. Check the reservoir level after the engine has cooled to be sure the coolant level is proper. Top off to the 'full' mark if its low

  • Chris L May 29, 2012

    courtesy ofhttp://www.gadgetjq.com/coolant_replacem... suggest anyone with a Vulcan 1500 to read... and donate to the website... awesome reference... can save a ton of money

×

Anonymous

Level 1:

An expert who has achieved level 1.

Corporal:

An expert that has over 10 points.

Mayor:

An expert whose answer got voted for 2 times.

  • Contributor 3 Answers
  • Posted on May 19, 2009
Anonymous
Contributor
Level 1:

An expert who has achieved level 1.

Corporal:

An expert that has over 10 points.

Mayor:

An expert whose answer got voted for 2 times.

Joined: May 19, 2009
Answers
3
Questions
0
Helped
5722
Points
13

Under the the gas tank

Ad

Add Your Answer

×

Uploading: 0%

my-video-file.mp4

Complete. Click "Add" to insert your video. Add

×

Loading...
Loading...

Related Questions:

0helpful
1answer

How do I refill coolant, after being drained, in a 2003 Kia Sedona. Radiator cap not removable. Doesn't seem to be taking any out of the reservoir.

Try this remov upper radiator hose from engine block and fill that way without running the engine. Then when radiator is full meaning can no longer add coolant through hose reconnect hose start engine and add coolant to reservoir
0helpful
1answer

Mazda 1999 B3000 what specifically needs to be replaced when transmission fluid get into the radiator?

The radiator must have an internal leak between the coolant and the reservoir for cooling the transmission fluid. Replace the radiator, drain and flush the engine and heater core, and drain and replace the transmission filter. You will need to remove the lower transmission pan, let it drain out (about 6 quarts), then replace the filter that is there, just underneath the pan. If you see any evidence of coolant in the transmission fluid, put it back together, run the vehicle for a bit-till the engine has warmed up, a short drive should do-then shut it off and drain the transmission fluid again.

When the transmission is drained this way, not all the transmission fluid will be drained-about half will still be in there, mostly in the torque converter. So if the fluid is contaminated, you need to drain and refill at least twice.
0helpful
1answer

1999 Kawasaki Vulcan 1500 Nomad engine oil capacity

there a small bolt missing on the front of my kawasaki 1500 nomad that r not there and a little fuel come out from time to time do u no what it call so i can get another one to put there ? and after changing the oil bike wont shift gears help ? only first gear
2helpful
1answer

Drained radiator to change coolant. How do you refill radiator when reservoir only takes about 3/4 of a quart? 2005 VULCAN 1500

Remove cap from radiator and fill this way, the meaning of the word reservoir remove oir from the end and you are left with the word reserve, the mass of the coolant is located in the radiator, the resovoir holds the coolant that is exsess when the engine is hot and the water has expanded,
5helpful
3answers

Losing coolant from the reservoir but cannot see any coolant leaking on drive. Fill reservior to MAX and within ~10miles, reservoir is drained. Refill while engine still hot and don't lose nearly as much...

my '01 Jetta had a similar problem. I could always smell coolant and the bottle was always low. I crawled under the car and there it was..a caked on mess of pink antifreeze. There is a plastic intersection 3 way valve where the coolant temp sensor resides. it has 2 bolts and a rubber o-ring. Because it is plastic, it cracks. it drips down onto areas which are really not visible from above and then sizzles and melts onto areas under the engine. The part was only about $25, took 30 min to install and my problem is now fixed. Air was getting into the system through the small crack in the valve further complicating the system operation.
2helpful
1answer

Where do i refill coolant? message reading low engine coolant.

please rate, thx Coolant Recovery System NOTE: When the water thermostat (8575) is closed, there is no flow through the radiator coolant recovery reservoir (8A080).

Trapped air in the cooling system must be removed. A pressurized radiator coolant recovery reservoir system is used which continuously separates the air from the cooling system.
  • When the water thermostat is open, coolant flows through the small hose from the top of the radiator outlet tank to the radiator coolant recovery reservoir.
  • The radiator coolant recovery reservoir separates any trapped air from the coolant and replenishes the system through its radiator coolant recovery hose to the water thermostat housing.
  • The radiator coolant recovery reservoir serves as the location for:
    • service fill
    • coolant expansion during warm-up
    • system pressurization from the pressure relief cap and
    • air separation during operation
  • The radiator coolant recovery reservoir is designed to have approximately 0.5-1 liter (0.53-1.06 quarts) of air when cold to allow for coolant expansion.

b203955.gif
1helpful
1answer

Where do you add coolant? To the Reservoir or the radiator?

always to the reservoir, never the radiator unless the system is being drained for service and refilled.
Not finding what you are looking for?

4,886 views

Ask a Question

Usually answered in minutes!

Top kawasaki Experts

Arnie Burke
Arnie Burke

Level 3 Expert

7339 Answers

Sean Wright
Sean Wright

Level 3 Expert

2045 Answers

Bob G

Level 2 Expert

104 Answers

Are you a kawasaki Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides

Loading...