Motorcycle engine cooling system Kawasaki ZX-6R/ZX-600-J (2000-2002)

Cooling system exploded view
1. Radiator Fan Switch; 2. Water Temperature Sensor; 3. Coolant By-pass Fitting; 4. Drain Plug; 5. Thermostat; 6. Cooling Hose Assembly; EO: Apply engine oil; L: Apply a non-permanent locking agent; SS: Apply silicone sealant. Т1: 5.9 N-m (0.60...

Cooling system specifications
Coolant provided when shipping Type — Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color — Green Mixed ratio — Soft water 50%, coolant 50% Freezing point...

Coolant flow chart
Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant...

Coolant deterioration inspection
Visually inspect the coolant in the reserve tank. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. If...

Coolant level inspection
Note. Check the level when the engine Is cold (room or ambient temperature). Check the coolant level in the reserve tank with the motorcycle held perpendicular. If the coolant level is lower than the low level line [A], add coolant to the full level...

Coolant draining
Warning! To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediately wipe up or wash...

Coolant filling
Remove: Lower Fairing (see Frame chapter ) Tighten the drain plug. Torque - Drain Plug: 9.8 N·m (1.0 kg·m, 95 in·lb) Fill the radiator up to the radiator filler neck [A] with coolant, and install the radiator cap. Note. C Pour in the coolant slowly...

Cooling system — pressure testing
Remove: Lower Fairing (see Frame chapter ). Remove the radiator cap, and install a cooling system pressure tester [A] on the filler neck. Note. Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. Build up pressure in the...

Cooling system — flushing
Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cooling system. If this accumulation is not removed, it will clog up the water...

Water pump — removal, installation and inspection
Removal Refer to Oil Pump Removal in Engine Lubrication System chapter. Installation Refer to Oil Pump Installation in Engine Lubrication System chapter. Inspection Check the drainage outlet passage [A] at the bottom of the water pump body for...

Radiator and radiator fan — removal
Warning! The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition switch is off. Never touch the radiator fan until the radiator fan connector is disconnected. Touching the fan before the connector is...

Radiator — inspection
Check the radiator core. If there are obstructions to air flow, remove them. ★ If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or...

Radiator cap — inspection
Check the condition of the top [A] and bottom [B] valve seals and valve spring [С]. If any one of them shows visible damage, replace the cap with a new one. Install the cap [A] on a cooling system pressure tester [B]. Note. Wet the cap sealing...

Thermostat — removal and installation
Removal Remove: Coolant (see Coolant Draining ) Seats (see Frame chapter ) Fuel Tank (see Fuel System chapter) Thermostat Housing Cover Bolts [A] Thermostat Housing Cover [B] Thermostat Installation Be sure to install the О-ring [A] on the housing...

Thermostat — inspection
Remove the thermostat, and inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one. To check vaive opening temperature, suspend the thermostat [A] in a container of water and raise the...

Hose — installation and inspection
Installation Install the hoses and pipes being careful to follow bending direction or diameter. Avoid sharp bending, kinking, flattening, or twisting. Install the clamps [A] as near as possible to the hose end to clear the raised rib or the fitting....

Radiator fan switch, water temperature sensor — removal and installation
Removal Caution! The fan switch or the water temperature sensor should never be allowed to fall on a hard surface. Such a shock to their parts can damage them. Drain the coolant (see Coolant Draining ). Remove: Radiator Fan Switch Lead Connectors...