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Pulsar 200 NS : DIY Coolant Replacement
Bike: Bajaj Pulsar 200 NS (Aug'12) (ODO : 20k km, First coolant change)
Couldn't find DIY for replacing coolant in xBhp. So black asp and I decided to make a thread. And I took a year to do that
. Anyway this is a relatively easy DIY for 200ns. And I guess steps will be similar for other bikes also.
Whole credit goes to black asp and his expertise, without his help I wouldn't have dared to do this!
Pulsar 200 NS as well both the Dukes comes pre-filled with Motul Inugel, this is a car coolant. This coolant should not be used in motorcycles.
Bajaj recommends to use Motul Motocool or Castrol Radicool.
I think Radicool isn't pre-mixed like motocool. Using radicool has a advantage of mixing it in different proportions of water according to need. I preferred using Motocool (so I didn't have to think about quality of distilled water available in my locality and also because my bike will be kept closed in garage for minimum of 3 months from now) And also because many of Bhubaneswar xBhpians used it and liked it .
I preferred to take a longer route for this coolant change so that no body panel gets damaged and to do work easily. You need not follow all steps, I followed all to flush each bit of Inugel and gunk
.
Tools Required :
Alternate process to access radiator and coolant reservoir.
Follow this procedure if you are not comfortable with opening tank cover. But do read the whole post, as I might have mentioned some warnings.
Follow other procedures to drain, flush and refill.
Procedure (To open seat and tank cover):
Remove rear seat and front seat. To remove front seat you need to use T-wrench.
Now you need to remove outer tank cover, so that radiator is accessible. (If you follow shorter route you wouldn't have to remove tank cover).
There are 10 bolts to remove tank, please mark them and keep them safely.
A pair star screws will be found after opening front seat.
Here there are two allen bolts on each side, remove those along with its washers. The allen bolt towards the front of bike has a rubber covering, you can remove it using your nails also there is a hole in centre, you can remove it by using a screw driver also.
Remove this bolt from both sides, it is accessible from front of bike.
Coolant drain pipe is connected through the tank cover, you need to remove drain pipe.
After removing this, tank cover can be removed easily.
Procedure : To drain coolant
Now remove reservoir cover/right side radiator cowl for easy accessibility. Just remove the two screws.
Then open two bolts, visible after opening reservoir cover. Remove the pipe from radiator cap and put it into the bowl.
Now open the reservoir cap, it is written coolant over it. Drain all coolant from the reservoir.
And clean the reservoir with water.
This is the reservoir. We called it heart
.
Keep bowl under the water pump drain bolt.
Open the drain bolt that is near water pump. Use L-wrench for it. Its a small bolt, a copper washer will also come out, that works as seal, clean them and keep them safely.
After opening drain bolt a small amount of coolant will come out.
Now open the radiator cap to remove all the coolant. You will also have to tilt bike to remove some leftover coolant.
Procedure : Flushing of radiator
Now close the drain bolt. Put a funnel in radiator and fill it with distilled water, tilt the bike towards left side, shake slightly, so that air bubbles come out and add water again till its full. Close the radiator cap. Run the engine for 5-10 minutes till its hot, then drain the water again following the procedure of draining. Wait more 10 minutes for engine to cool, then redo these processes 2 times.
NOTE: Don't put water immediately after draining, you know what happens when you put water on hot metal .
Now we will use vinegar to flush the radiator.
Vinegar is mild acid, so it also has bad effects on rubber, plastic and metal. People say not to use it in engines having aluminium block. More info you can find by using Google Baba.
Anyway I used it as I think it will have no harm in immediate flush. There is no case in internet where people had problem in engine by using vinegar when they did immediate flush.
You may or may not follow this step. Its completely on your decision.
We made a dilute mixture of distilled water and distilled vinegar in 50:50 proportion. Then flushed using it, following the steps mentioned above for flushing using distilled water. After flushing twice with vinegar, we flushed again twice with distilled water.
NOTE: try to heat the engine till fan starts running, mine took more than 15 minutes.
Note the colour of drained mixture of vinegar, it was completely transparent while it was filled in radiator, some gunk particles also came out.
Procedure : Refilling the coolant
Now install the reservoir tank.
Here replace the copper washer with a new one. It is highly recommended to replace copper washer every-time along with coolant.
The procedure of filling the coolant is same as the initial procedure of flushing. Put coolant in small amounts and then tilt and shake the bike so that very less air bubbles stay inside. After filling radiator upto its brim, close the radiator cap.
Now connect the pipe from reservoir to radiator cap.
Now fill the reservoir till max, close the cap. Later the coolant level might decrease after leftover air comes out, don't worry till it's above minimum.
Now connect the coolant drain pipe from tank cover to reservoir. And reassemble the tank in the exact reverse procedure. And do not over tighten the bolts of tank, it can break the tank cover. Route the drain pipe correctly after complete installation.
DISCLAIMER
I take utmost care and caution in doing this with all risks vested upon me. While the outcome may vary on each bike, I strongly recommend you to completely understand your bike and then go ahead with similar DIYs. Though I would be glad to answer any of your questions I am not responsible for any kind of outcome of such DIY. Please take help and clarify before gettings your hands greasy!!!
P.S.:I used some images from Google to explain correctly.
Thank You
And a lot of thanks to Parvez Bhai aka black asp
Sent from my Nexus 5 using Tapatalk
Couldn't find DIY for replacing coolant in xBhp. So black asp and I decided to make a thread. And I took a year to do that
. Anyway this is a relatively easy DIY for 200ns. And I guess steps will be similar for other bikes also.Whole credit goes to black asp and his expertise, without his help I wouldn't have dared to do this!
Pulsar 200 NS as well both the Dukes comes pre-filled with Motul Inugel, this is a car coolant. This coolant should not be used in motorcycles.
Bajaj recommends to use Motul Motocool or Castrol Radicool.
I think Radicool isn't pre-mixed like motocool. Using radicool has a advantage of mixing it in different proportions of water according to need. I preferred using Motocool (so I didn't have to think about quality of distilled water available in my locality and also because my bike will be kept closed in garage for minimum of 3 months from now) And also because many of Bhubaneswar xBhpians used it and liked it .
I preferred to take a longer route for this coolant change so that no body panel gets damaged and to do work easily. You need not follow all steps, I followed all to flush each bit of Inugel and gunk
.Tools Required :
- Socket T-wrench of size 10
- Socket L-wrench of size 10
- Star Screwdriver
- Allen Key of size 5
- Distilled water and Vinegar (if you follow all steps)
- Coolant
- Coolant drain bolt washer (Copper washer, it is recommended to replace every time along with coolant)
- Funnel
- A big bowl (to collect waste water and coolant. Be Environment Friendly
) - A place to keep all bolts safely and keep all marked (many bolts are of same size but of different lengths)
Alternate process to access radiator and coolant reservoir.
Follow this procedure if you are not comfortable with opening tank cover. But do read the whole post, as I might have mentioned some warnings.
- Open right radiator cowl.
- Open the bolts, remove the coolant drain pipe.
- Bring the reservoir out of its mounting place. Drain the coolant in reservoir by turning it upside down.
- Access the radiator cap from front of bike.
Follow other procedures to drain, flush and refill.
Procedure (To open seat and tank cover):
Remove rear seat and front seat. To remove front seat you need to use T-wrench.
Now you need to remove outer tank cover, so that radiator is accessible. (If you follow shorter route you wouldn't have to remove tank cover).
There are 10 bolts to remove tank, please mark them and keep them safely.
A pair star screws will be found after opening front seat.
Here there are two allen bolts on each side, remove those along with its washers. The allen bolt towards the front of bike has a rubber covering, you can remove it using your nails also there is a hole in centre, you can remove it by using a screw driver also.
Remove this bolt from both sides, it is accessible from front of bike.
Coolant drain pipe is connected through the tank cover, you need to remove drain pipe.
After removing this, tank cover can be removed easily.
Procedure : To drain coolant
Now remove reservoir cover/right side radiator cowl for easy accessibility. Just remove the two screws.
Then open two bolts, visible after opening reservoir cover. Remove the pipe from radiator cap and put it into the bowl.
Now open the reservoir cap, it is written coolant over it. Drain all coolant from the reservoir.
And clean the reservoir with water.
This is the reservoir. We called it heart
. Keep bowl under the water pump drain bolt.
Open the drain bolt that is near water pump. Use L-wrench for it. Its a small bolt, a copper washer will also come out, that works as seal, clean them and keep them safely.
After opening drain bolt a small amount of coolant will come out.
Now open the radiator cap to remove all the coolant. You will also have to tilt bike to remove some leftover coolant.
Procedure : Flushing of radiator
Now close the drain bolt. Put a funnel in radiator and fill it with distilled water, tilt the bike towards left side, shake slightly, so that air bubbles come out and add water again till its full. Close the radiator cap. Run the engine for 5-10 minutes till its hot, then drain the water again following the procedure of draining. Wait more 10 minutes for engine to cool, then redo these processes 2 times.
NOTE: Don't put water immediately after draining, you know what happens when you put water on hot metal .
Now we will use vinegar to flush the radiator.
Vinegar is mild acid, so it also has bad effects on rubber, plastic and metal. People say not to use it in engines having aluminium block. More info you can find by using Google Baba.
Anyway I used it as I think it will have no harm in immediate flush. There is no case in internet where people had problem in engine by using vinegar when they did immediate flush.
You may or may not follow this step. Its completely on your decision.
We made a dilute mixture of distilled water and distilled vinegar in 50:50 proportion. Then flushed using it, following the steps mentioned above for flushing using distilled water. After flushing twice with vinegar, we flushed again twice with distilled water.
NOTE: try to heat the engine till fan starts running, mine took more than 15 minutes.
Note the colour of drained mixture of vinegar, it was completely transparent while it was filled in radiator, some gunk particles also came out.
Procedure : Refilling the coolant
Now install the reservoir tank.
Here replace the copper washer with a new one. It is highly recommended to replace copper washer every-time along with coolant.
The procedure of filling the coolant is same as the initial procedure of flushing. Put coolant in small amounts and then tilt and shake the bike so that very less air bubbles stay inside. After filling radiator upto its brim, close the radiator cap.
Now connect the pipe from reservoir to radiator cap.
Now fill the reservoir till max, close the cap. Later the coolant level might decrease after leftover air comes out, don't worry till it's above minimum.
Now connect the coolant drain pipe from tank cover to reservoir. And reassemble the tank in the exact reverse procedure. And do not over tighten the bolts of tank, it can break the tank cover. Route the drain pipe correctly after complete installation.
DISCLAIMER
I take utmost care and caution in doing this with all risks vested upon me. While the outcome may vary on each bike, I strongly recommend you to completely understand your bike and then go ahead with similar DIYs. Though I would be glad to answer any of your questions I am not responsible for any kind of outcome of such DIY. Please take help and clarify before gettings your hands greasy!!!
P.S.:I used some images from Google to explain correctly.
Thank You
And a lot of thanks to Parvez Bhai aka black asp
Sent from my Nexus 5 using Tapatalk
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