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Discussion Starter #1
I installed the heater kit per downloaded instructions but found the heater doesn't seem to completely shut off.. stays warm when on cold and very hot when on hot.. on review of instructions and then the Kawasaki video, I found that the video appears to have the heater core backwards from the written instructions.. the video has the heater inlet hooked to the suction side or return coolant line to engine.. the written instructions show just the opposite... although the written instructions appear to be correct it too show the heater return or coolant suction line Y fitting in backwards..
I will see if I can post the pictures.. on the video look for frame 6:05 6:06... on the written instruction look on page 11 of 21 third photo down.. the installation overview diagram appears to be the correct way on page 4
457
 

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Discussion Starter #5
I see no conflict, both say and show the same thing
its been some time since I discovered the mistake and contacted Kawi.. I haven't revisited the video but looks like they have removed it.. the picture above #03 correct in this picture was reversed caused angle of heater pipe to flow into from rad not out of heater to return on written instruction picture.. the performance valve #02 was being connected to the return hose on the original video..
I posted this to give anyone trying to install the heater kit a heads up as its was hard enough to do the install without having it hooked up incorrectly...
are you trying to install the heater kit?
 

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its been some time since I discovered the mistake and contacted Kawi.. I haven't revisited the video but looks like they have removed it.. the picture above #03 correct in this picture was reversed caused angle of heater pipe to flow into from rad not out of heater to return on written instruction picture.. the performance valve #02 was being connected to the return hose on the original video..
I posted this to give anyone trying to install the heater kit a heads up as its was hard enough to do the install without having it hooked up incorrectly...
are you trying to install the heater kit?
Yes, installed the heater but have a leak at the water valve. When the valve is turned the O ring is leaking. Manufacturers were really cool and are sending a new valve out ASAP.
 

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its been some time since I discovered the mistake and contacted Kawi.. I haven't revisited the video but looks like they have removed it.. the picture above #03 correct in this picture was reversed caused angle of heater pipe to flow into from rad not out of heater to return on written instruction picture.. the performance valve #02 was being connected to the return hose on the original video..
I posted this to give anyone trying to install the heater kit a heads up as its was hard enough to do the install without having it hooked up incorrectly...
are you trying to install the heater kit?
Ok. Now I see what your saying. I did install the Y pipe like page 11 and the angle is the wrong way. Will have to see if I can turn it around. I can see how it would affect the heater at idle speeds. Hope the radiator hose will still work or I will need to replace it and cut it farther back.
 

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Discussion Starter #8
ok.. so on the performance valve.. it was causing a lot of fluctuations in engine operating temperature. when it finally did settle down it ran hotter than it did before the heater install.. the heater performance valve thermostat stoped the flow of coolant into the radiator and runs it through the heater core first before opening.. Great in the winter but not so much in the summer and the heater core never cooled down even with the temp switch on cool.
I just took the thermostat out a 195deg is too high for what its intended use is here IMO and sealed up the housing. then installed an additional manual inline 5/8" shut off on the return side just below the core on the drivers side.. Now the engine temp is normal and the heater core gets cold for the summer months..
yea I have to reach down under the dash and flip the manual valve for the winter but worth the trouble in the summer.. the con is without a thermostat in the valve the heater may take a few more minutes to get warm and maybe doesn't get as super hot as it does with the thermostat but works good this way for me..
ideally a lower temp thermostat like a 165 or 180 may work better in colder climate..
 

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Discussion Starter #9
Ok. Now I see what your saying. I did install the Y pipe like page 11 and the angle is the wrong way. Will have to see if I can turn it around. I can see how it would affect the heater at idle speeds. Hope the radiator hose will still work or I will need to replace it and cut it farther back.
if you already installed the y pipe like I did before I discovered it.. I just left it.. decided it wasn't worth the pita it would be to dig and replace the section of return radiator hose..
 

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ok.. so on the performance valve.. it was causing a lot of fluctuations in engine operating temperature. when it finally did settle down it ran hotter than it did before the heater install.. the heater performance valve thermostat stoped the flow of coolant into the radiator and runs it through the heater core first before opening.. Great in the winter but not so much in the summer and the heater core never cooled down even with the temp switch on cool.
I just took the thermostat out a 195deg is too high for what its intended use is here IMO and sealed up the housing. then installed an additional manual inline 5/8" shut off on the return side just below the core on the drivers side.. Now the engine temp is normal and the heater core gets cold for the summer months..
yea I have to reach down under the dash and flip the manual valve for the winter but worth the trouble in the summer.. the con is without a thermostat in the valve the heater may take a few more minutes to get warm and maybe doesn't get as super hot as it does with the thermostat but works good this way for me..
ideally a lower temp thermostat like a 165 or 180 may work better in colder climate..
Called the manufacturer again. They said with the Y fitting the wrong way it will cause the temp fluctuation. So I ordered a new lower rad hose and when they send me the new valve that was leaking I will turn the Y the correct.
 
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