DS525X Coolant Change

The DS525X engine is water cooled. The owner's manual calls for replacing the coolant every two years Owner's manual p. 73. Its maintenance table marks the coolant "2 years" and also replaces it at 37,000 km, and inspects the coolant level at every service Owner's manual p. 89. The Hungarian owner's manual also replaces the coolant every two years.

The owner's manual and the KEL500F engine workshop manual describe the drain and the air bleed differently. This page shows both methods. We cannot verify which is correct. The Hungarian owner's manual is a machine translation and its introduction names an older model (Valico 500DS/500DSX), so treat values that appear only there with caution. It gives no coolant change procedure.

Specifications

Where the manuals give different values, each value is listed with its sources and the row is marked Sources differ. We cannot verify which value is correct.

Warnings from the manuals

• Hot coolant. Let the engine cool before opening the radiator cap, or hot coolant can spray out and scald you.
• Dry expansion tank. If the expansion tank has run completely dry, do not simply fill it. Air has entered the system and must be bled out first, which the owner's manual says only a VOGE authorized distributor can do.
• Frequent topping up points to a fault. Contact a VOGE authorized distributor.
• No running water. Filling with running water is not allowed and may damage the cooling system.
• No mixing. Do not mix coolants of different specifications.
• No silicate coolant. Coolant with silicate corrosion inhibitors may wear the water pump seal ring faster and block the radiator passages.
• Paint. Keep coolant off painted surfaces.
• No overfilling. Coolant expands as it warms and can be pushed out of the overflow tube.

What you need

• Coolant to the specification above, at least 1.5 L
• New flat washers for the drainage bolts
• Torque wrench
• Drain pan, funnel and rags

Procedure: owner's manual method

From the owner's manual p. 72-73. Work on a cool engine.

1. Hold the motorcycle upright on the parking stand (technique guide) and put a dish under the engine.
2. Remove the water drainage bolt. The cooling system is connected, so all the coolant can flow out of that port.
3. When the coolant has fully drained, refit the drainage bolt.
4. Open the radiator cap and fill with coolant.
5. Keep filling while squeezing the water hose to push out air, until the radiator is full. Then screw the cap on.
6. Start the engine and run it for 30 seconds so the coolant reaches every part.
7. Stop the engine. When it has cooled, open the radiator cap again. If the level has dropped, fill it up again. Repeat as often as needed.
8. Remove the black rubber cap on the expansion tank and fill until the level is between UPPER and LOWER.

Procedure: workshop manual method

From the KEL500F engine workshop manual p. 37-38. Keep the bike upright on level ground when filling or checking.

1. Remove the cooling fan fairing.
2. Remove the drainage bolt and flat washer on the water pump. Remove the radiator cap and drain the coolant.
3. Remove the drainage bolt and flat washer on the cylinder head and drain the coolant.
4. Fit new flat washers and refit both bolts. Tighten the water pump bolt to 10 N·m and the cylinder head bolt to 12 N·m.
5. Disconnect the siphon tube from the radiator and pull it out of its clamp. Lower the hose outside the frame and drain the coolant from the storage tank. Wash the inside of the tank with water, then refit the hose in its clamp.
6. Fill the system with the recommended coolant through the filler until it reaches the filler neck.
7. Bleed the air: put the engine in neutral, start it and let it idle for 2-3 minutes. Open and close the throttle 3-4 times. Stop the engine and top up if needed. Then fit the radiator cap.
8. Fill the storage tank with the recommended coolant and refit the fairing.

The owner's manual runs the engine with the cap on and tops up after each cool-down. The workshop manual idles the engine with the cap off and blips the throttle. We cannot verify which is correct.

Leak and pressure check

The workshop manual checks for leaks with a cooling system tester after any work on the system. On p. 36 the radiator cap must hold 108-137 kPa for at least 6 seconds, and the system test pressure must not go above 137 kPa.

Disposal

Dispose of the old coolant in an environmentally friendly way.

Cross-reference

The DS525X's KEL500F and the DS625X's KEL600 use the same coolant specification in their owner's manuals but hold different amounts. Values below are from the DS525X owner's manual p. 73 and the DS625X owner's manual p. 73.

Sources

• Voge DS525X owner's manual (English)
• KEL500F engine workshop manual
• DS525X owner's manual (Hungarian), machine translated

Have notes on bleed quirks or hose-clip locations? Send them in.