Instruction/ maintenance manual of the product KX65 Kawasaki
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KX65 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical phot.
LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa .
This motorcycle is designed for a rider weighing less than 121 pounds (55 kg). Exceeding this limit could damage the motorcycle. Read OWNER’S MANUAL before operating.
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However , it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work.
GENERAL INFORMA TION 1-1 1 General Information T able of Contents Before Servicing ................................................................................................................ ..... 1-2 Model Identification.........................
1-2 GENERAL INFORMA TION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the preca utions given below .
GENERAL INFORMA TION 1-3 Before Servicing (1 1) Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12) Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary .
1-4 GENERAL INFORMA TION Before Servicing (19) Inspection When parts have been disassembled, visually in spect these pa rts for the following conditions or other damage.
GENERAL INFORMA TION 1-5 Model Identification K X 6 5 - A 1L e f tS i d eV i e w KX65-A1 Right Side View.
1-6 GENERAL INFORMA TION General Specifications Items KX65-A1 ∼ A2 KX65-A3 ∼ A6, A6F ∼ Dimensions Overall Length 1 580 mm 1 590 mm Overall Width 690 mm (KX65-A1), 730 mm (KX65-A2) 760 mm Overall.
GENERAL INFORMA TION 1-7 General Specifications Items KX65-A1 ∼ A2 KX65-A3 ∼ A6, A6F ∼ Drive T rain Primary Reduction System: Ty p e Gear ← Reduction Ratio 3.500 (77/22) ← Clutch T ype Wet , m u lt i d is c ← T ransmission: Ty p e 6-speed, constant mesh, return shift ← Gear Ratios: 1st 2.
1-8 GENERAL INFORMA TION General Specifications Items KX65-A1 ∼ A2 KX65-A3 ∼ A6, A6F ∼ Brake T ype: Front and Rear Single disc ← Effective Disc Diameter: ← Front 164.8 mm ← Rear 146 mm ← Specifications are subject to change without notice, and may not apply to every country .
GENERAL INFORMA TION 1-9 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good run ning condition. FREQUENCY OPERA TION After each race (or 2.5 hr .) Every 3 races (or 7.5 hr .) Every 5 races (or 12.
1-10 GENERAL INFORMA TION Periodic Maintenance Chart FREQUENCY OPERA TION After each race (or 2.5 hr .) Every 3 races (or 7.5 hr .) Every 5 races (or 12.
GENERAL INFORMA TION 1- 1 1 T orque and Locking Agent T ighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out.
1-12 GENERAL INFORMA TION T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Engine Removal/Installation Engine Mounting Nuts 25 2.5 18 Engine Mounting Nuts (KX65-A3 ∼ ) 29 3.0 21 Swing Arm Pivot Shaft Nut 69 7.0 51 Engine Bottom End/T ransmission Cylinder Stud – – – L (Planted Side) Crankcase Bolts 8.
GENERAL INFORMA TION 1-13 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Rocker Arm Pivot Nut 83 8.5 61 Caliper Mounting Bolts 25 2.5 18 Rear Frame Mounting Bolts 34 3.5 25 Steering Steering Stem Head Nut 44 4.5 33 Steering Stem Nut 2.
1-14 GENERAL INFORMA TION Special T ools and Sealants Bearing Puller Adapte r: 57001-136 Steering Stem Bearing Dr iver: 57001-137 Inside Circl ip Pliers: 57001-143 Outside Circlip Pliers: 57001-144 Bearing Pulle r: 57001-158 Fork Cylinder Holder Handle: 57001-183 Flywheel Puller , M 12 × 1.
GENERAL INFORMA TION 1-15 Special T ools and Sealants Rim Protec tor: 57001-1063 Bead Breaker Assembly: 57001-1072 Head Pipe Outer Race Pre ss Shaft: 57001-1075 Steering Stem Bear ing Driver Adapt er , 29.7: 57001-1092 Steering Stem Nu t Wrench: 57001-1 100 Hook Wrench R37.
1-16 GENERAL INFORMA TION Special T ools and Sealants Front Fork Oil Seal Driver: 57001-121 9 Jack: 57001-123 8 Fork Oil Level Ga uge: 57001-129 0 Crankcase Splitt ing T ool Assembly: 57001-136 2 Hand.
GENERAL INFORMA TION 1-17 Special T ools and Sealants Kawasaki Bond (Sil icone Sealant): 56019-120 Kawasaki Bond (Liquid Gasket - Silver): 92104-002.
1-18 GENERAL INFORMA TION Cable, Wire and Hose Routing 1. Throttle Cable 2. Carburetor 3. Breather Hose 4. Air V ent H ose 5. Overflow Hose 6. The hoses are passed from the left side of the engine through the clamp in order of the air vent hose, the overflow hose and the breather hose as shown in figure.
GENERAL INFORMA TION 1-19 Cable, Wire and Hose Routing 1. Breather Hose 2. Run the throttle cable under the breather hose. 3. Radiator 4. CDI Unit (KX65-A1 ∼ A6) 5. Clamp (KX65-A1 ∼ A6) 6. Throttle Cable 7. Clamp as shown in figure. (Be sure the clamp screw position is inside.
1-20 GENERAL INFORMA TION Cable, Wire and Hose Routing 1. Clamp 2. CDI Unit (KX65-A1 ∼ A6) 3. Band 4. Clamp the magneto leads at the upper part of the left on the carburetor holder . 5. Magneto Leads 6. Shift Pedal 7. 19 ±10 mm (Shift Pedal Position) 8.
GENERAL INFORMA TION 1-21 Cable, Wire and Hose Routing 1. Front Brake Reservoir 2. Banjo Bolts 3. Clamp 4. Front Brake Disk 5. Bleed V alves 6. Front Brake Caliper 7. Rear Brake Caliper 8. Rear Brake Disk 9. Rear Brake Reservoir 10. Rear Brake Master Cylinder 1 1.
1-22 GENERAL INFORMA TION Cable, Wire and Hose Routing KX65A6F ∼ 1. Throttle Cable 2. Clutch Cable 3. Band 4. Engine Stop Button Lead 5. Clamp 6. CDI unit 7. Band 8. CDI unit Ground Lead 9. Ignition Coil Primary Lead 10. Ignition Coil Ground Lead 1 1.
FUEL SYSTEM 2-1 2 Fuel System T able of Contents Exploded View ................................................................................................................... ..... 2-2 Specifications ...............................................
2-2 FUEL SYST EM Exploded View 1. Throttle Cable 2. Throttle Grip 3. Carburetor Holder 4. Carburetor Cap 5. Spring 6. Retainer 7. Jet Need le Clip 8. Jet Needle 9. Throttle V alve 10. Choke Knob 1 1. Idle Adjusting Screw 12. Spring 13. Air Screw 14. Slow Jet 15.
FUEL SYSTEM 2-3 Exploded View 1. Fuel T ank Cap 2. Fuel T ank 3. Fuel T ap 4. Air Cleaner Housing 5. Element 6. Frame 7. Holder 8. Air Cleaner Duct T1: 34 N·m (3.5 kgf·m, 25 ft·lb) T2: 8.8 N·m (0.90 kgf·m, 78 in·lb) T3: 3.0 N·m (0.31 kgf·m, 27 in·lb) G: Apply grease.
2-4 FUEL SYST EM Specifications Standard Item KX65-A1 ∼ A2 KX65-A3 ∼ Service Limit Throttle Grip Free Play and Cable 2 ∼ 3m m ← ––– Carburetor Make/T ype MIK UNI VM24SS ← ––– Main Jet #230 #190 ––– Throttle V alve Cutaway #2 #1.
FUEL SYSTEM 2-5 Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or mis-adjustment, there will be a delay in throttle response.
2-6 FUEL SYST EM Throttle Grip and Cable Cable Lubrication Whenever the cable is removed, and in accordan ce with the Periodic Maintenance Chart (see General Information chapter), do the following. • Apply a thin coating of grease [A] to the cable upper end.
FUEL SYSTEM 2-7 Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear , maladjustment, or improper fuel level in the float chamber .
2-8 FUEL SYST EM Carburetor • Remove the carburetor , and hold it in true vertical position on a stand. The fuel hose and carburetor cable do not have to be removed to inspect the fuel level [A]. • Put the fuel tank on a bench, and connect the fuel tap to the carburetor using a suitable hose.
FUEL SYSTEM 2-9 Carburetor • Drive out the pivot pin [A] and remove the float [B]. • Bend the tang [A] on the float arm very slightly to change the float height. Increasing the float heigh t lowers the fuel level and decreasing the float height raises the fuel level.
2-10 FUEL SYSTEM Carburetor • Unscrew the carburetor cap [A], and pull out the throttle valve assembly [B]. CAUTION If the throttle valve is left attached to the cable, wrap it in a clean cloth to avoid damage.
FUEL SYSTEM 2-1 1 Carburetor • T urn the fuel tap to the ON position, and check for fuel leakage from the carburetor . WA R N I N G Fuel spilled from the carburetor is hazardous.
2-12 FUEL SYSTEM Carburetor ○ Slide the jet needle out of the throttle valve. ○ Pull out the snap ring [A], and remove the throttle cable from the carburetor cap [B].
FUEL SYSTEM 2-13 Carburetor CAUTION Do not use compressed air on an assembled carbu- retor , the float may be deformed by the pressure. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbu- retor with a cleaning solution.
2-14 FUEL SYSTEM Carburetor • Check the tapered portion [A] of the pilot screw [B] for wear or damage. If the pilot screw is worn or damaged on the tapered por- tion , it will prevent the engine from idling smoothly . Re- place it. • Remove the float valve needle [B].
FUEL SYSTEM 2-15 Air Cleaner Air Cleaner Housing Re moval • Remove: Radiator Shrouds Side Covers Seat Rear Fender Rear Flap Rear Frame Mounting Bolts [A] Rear Frame [B] Air Cleaner Housing Mounting Bolts [C] • Loosen the air cleaner duct clamp [D].
2-16 FUEL SYSTEM Air Cleaner • Install the element [A]. ○ The element tab [B] position is put on whichever of the holder . Element Cleaning and In spection NOTE ○ In dusty areas, the element should be cleaned more frequently than recommended interval.
FUEL SYSTEM 2-17 Fuel T ank Fuel T an k Removal WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
2-18 FUEL SYSTEM Fuel T ank Fuel T ap In spection • Remove the fuel tap. • Check the fuel tap filter screen [A] for any breaks or dete- rioration. If the fuel tap screen have any breaks or is deteriorated, it may allow dirt to reach the carburetor , causing poor run- ning.
FUEL SYSTEM 2-19 Reed V alve Reed V alve Removal • Remove the carburetor holder mounting bolts and carbu- retor holder [A]. • Remove the reed valve [B] out of the cylinder .
2-20 FUEL SYSTEM Fuel Hose Fuel Hoses and Connections Check ○ Check the fuel hose periodically in accordance with the Periodic Maintenance Chart, and if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A] or the hose to burst.
COOLING SYSTEM 3-1 3 Cooling System T able of Contents Exploded View ................................................................................................................... ..... 3-2 Specifications .........................................
3-2 COOLING SYSTEM Exploded View 1. Radiator 2. Radiator Cap 3. W ater Pump Cover 4. Drain Plug 5. Impeller 6. Oil Seal (Short) 7. Oil Seal (Long) 8. Bearing 9. W ater Pump Gear 10. Right Engine Cover 1 1. Cylinder Head 12. Cylinder 13. Air Bleeder Bolt T1: 8.
COOLING SYSTEM 3-3 Specifications Item Standard Coolant Ty p e Permanent type antifreeze for aluminum engines and radiators Color Green Mixed ratio Soft water 50%, coolant 50% T otal amount 0.4 L Radiator Cap relief pressure 108 ∼ 137 kPa (1.1 ∼ 1.
3-4 COOLING SYSTEM Coolant Check the coolant level each day before riding the motor- cycle, and replenish coolant if the level is low . Change the coolant in accordance with the Periodic Maintenance Chart (see General Information chapter).
COOLING SYSTEM 3-5 Coolant Coolant Draining The coolant should be changed periodically to ensure long engine life. WA R N I N G T o avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. W ait until it cools down.
3-6 COOLING SYSTEM Coolant • Install the coolant drain plug. ○ Replace the gasket with a new one. T orque - Coolant Drain Plug ( W ater Pump): 8.8 N· m (0.90 kgf·m, 78 in·lb) • Fill the radiator up to the bottom of the radiator filler neck [B] with coolant [A], and install the cap, turning it clockwise about 1/4 turn.
COOLING SYSTEM 3-7 Coolant • Build up pressure in the system carefully until the pres- sure reaches 123 kPa (1.25 kgf/cm², 18 p si). • W atch the gauge for at least 6 seconds. If the pressure holds steady , the cooling system is all right. • Remove the pressure tester , replenish the coolant, and install the radiator cap.
3-8 COOLING SYSTEM Disassembly and Assembly Precautions • Prior to disassembly of cooling system parts (radiator , pump, etc), wait until the coolant cools down, and then drain the coolant. • After assembling and filling t he system with coolant, bleed any air from the system.
COOLING SYSTEM 3-9 Wa t e r P u m p Water Pump Cover Removal • Drain the coolant (see Coolant Draining). • Loosen the water hose clamps [A], and disconne ct the water hoses on the water pump cover [B]. • Unscrew the cover bolts [C], and remove the water pump cover .
3-10 COOLING SYSTEM Wa t e r P u m p Wat e r P u mp S h a ft R e m o v al • Remove: Right Engine Cover (see Engine Right Side chapter) • Remove the circlip [A], and pull off the primary gear [B]. Special T ool - Outside Circlip Pliers: 57001-144 KX65A6F ∼ : • Remove the primary gear [B] (see Engine Right Side chapter).
COOLING SYSTEM 3-1 1 Wa t e r P u m p • Press the ball bearing [A] into the hole until the bearing is bottomed against the step [B]. Special T ools - Bearing Driver Set: 57001-1 129 • Apply plenty of high temperature grease t o the oil seal lips [D].
3-12 COOLING SYSTEM Radiator Radiator Removal • Drain the coolant (see Coolant Draining). • Remove: Left Shroud [A] Wa t e r H o s e [ B ] Radiator Mounting Bolts [C] Radiator Screen [D] Breather Hose Radiator [E] Radiator Installation • Radiator installation is the reverse of removal.
COOLING SYSTEM 3-13 Radiator Cap Inspection • Check the condition of the valve spring [B], and the top and bottom valve seals [A] of the radiator cap. If any one of them shows visible damage, replace the cap. • Wet the top and bottom valve seals with water or coolant to prevent pressure leaks.
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ENGINE TOP END 4-1 4 Engine T op End T able of Contents Exploded View ................................................................................................................... ..... 4-2 Specifications ........................................
4-2 ENGINE TOP END Exploded View 1. Spark Plug 2. Cylinder Head 3. Cylinder 4. Piston Ring 5. "1N" Mark 6. "2N" Mark 7. Piston 8. "IN" Mark 9. Piston Pin 10. Expansion Chamber 1 1. Rubber Seal 12. Gasket 13. Muffler Body (KX65-A1 ∼ A2) T1: 25 N·m (2.
ENGINE TOP END 4-3 Specifications Item Standard Service Limit Cylinder Head Cylinder Compression (Usable range) ––– 755 ∼ 1 177 kPa (7.70 ∼ 12.0 kgf/cm², 109 ∼ 171 psi) Cylinder head warp ––– 0.03 mm Cylinder , P iston Cylinder Inside Diameter (15 mm below from the Cylinder T op End) 44.
4-4 ENGINE TOP END Cylinder Head Cylinder Compression Measurement • Start the engine. • Thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. • Stop the engine.
ENGINE TOP END 4-5 Cylinder Head Cylinder Head Installation • Replace the head gasket with a new one. • Scrape out any carbon and clean the head with a high flash-point solvent. • Check for a crust of minerals and rust in the head water jacket, and remove them if necessary .
4-6 ENGINE TOP END Cylinder Cylinder Removal • Drain the coolant (see Cooling System chapter). • Remove: Cylinder Head (see this chapter) Carburetor (see Fuel System chapter) W ater Hose Upper End Clutch Cable Lower End Muffler Holding Springs • Remove the cylinder nuts [A].
ENGINE TOP END 4-7 Cylinder Piston Installation • Stuff a clean cloth into the crankcase opening around the connecting rod so that no parts will fall into the crankcase. • Scrape off any carbon of t he piston, then lightly polish the piston with fine emery cloth.
4-8 ENGINE TOP END Cylinder Cylinder Wear Inspection NOTE ○ Measure the cylinder inside diameter when the cylinder is cold (room or ambient temperature). • Visually Inspect the inside of the cylinder for scratches and abnormal wear . If the cylinder is damaged or badly worn, replace it with a new one.
ENGINE TOP END 4-9 Cylinder Piston Ring, Piston Ring Groove Inspectio n • Visually inspect the piston rings and the piston ring grooves. If the rings are worn unevenly or damaged, they must be replaced. If the piston ring grooves are worn unevenly or damaged, the piston must be replaced and fitted with new rings.
4-10 ENGINE TOP END Cylinder Piston, Piston Pin, Connecting Rod Wear Inspection • Visually inspect the snap ring [A] still fitted in place. If the ring shows weakness or deformation, replace the ring. Also if the pin hole groove shows excessive wear , replace the piston.
ENGINE TOP END 4-1 1 Muffler (Expansion Chamber) Muffler Removal • Remove: Right Shroud Right Side Cover • Remove the muf fler mounting bolts [B] and pull the muffler [A] off toward the rear . • Remove the springs [A] holding t he exhaust pipe holding .
4-12 ENGINE TOP END Muffler (Expansio n Chamber) • Unscrew the inner pipe mounting bolts [A]. • Pull the inner pipe [B] from the muf fler body . • Pull off the old muf fler baf fle, and install the new muffler baffle [A] into the muf fler body .
ENGINE RIGHT SIDE 5-1 5 Engine Right Side T able of Contents Exploded View ................................................................................................................... ..... 5-2 Specifications ...................................
5-2 ENGINE RIGHT SIDE Exploded View.
ENGINE RIGHT SIDE 5-3 Exploded View 1. Clutch Lever 2. Clutch Cable 3. Release Lever Shaft 4. Clutch Pusher 5. Shim(s) 6. Spring Plate Pusher 7. Clutch Hub 8. Clutch Wheel 9. Friction Plate 10. Steel Plate 1 1. Clutch Housing 12. Sleeve 13. Primary Gear 14.
5-4 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Clutch Lever Free Play 2 ∼ 3m m ––– Friction Plate Thickness 3.1 ∼ 3.3 mm 2.9 mm Steel Plate Thickness 1.47 ∼ 1.73 mm 1.37 mm Friction Plate W arp Not more than 0.2 mm 0.3 mm Steel Plate W arp Not more than 0.
ENGINE RIGHT SIDE 5-5 Clutch Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WA R N I N G T o avoid a serious burn, never touch the hot engine or exhaust chamber during clutch adjustment.
5-6 ENGINE RIGHT SIDE Clutch Cable • Free the clutch inner cable tip from the clutch release lever . CAUTION Do not remove the clutch release shaft unless it is absolutely necessary . If removed, release shaft oil seal must be replaced with a new one.
ENGINE RIGHT SIDE 5-7 Right Engine Cover Right Engine Cover Removal • Drain the engine oil (see Engine Oil Change in the Engine Bottom End/T ransmission chapter).
5-8 ENGINE RIGHT SIDE Right Engine Cover • When the release lever [A] is turned to the right [B] lightly , choose the amount of shims [C] on the clutch pusher [D] so that the included angle between the release lever [ A] and the line [E] at the right angle to the right engine cover is approx.
ENGINE RIGHT SIDE 5-9 Right Engine Cover Right Engine Cover Disassembly • Remove the right engine cover (see this chapter). • Pull out the clutch release shaft [A]. CAUTION Do not remove the clutch release shaft unless it is absolutely necessary .
5-10 ENGINE RIGHT SIDE Clutch Clutch Removal • Remove the right engine cover (see Right Engine Cover Removal). • Remove the clutch pusher [A], shim [B] (as required) and spring plate pusher [C]. • Remove the magneto cover . • Hold the magneto flywheel steady with flywheel & pulley holder [A].
ENGINE RIGHT SIDE 5-1 1 Clutch CAUTION If dry steel plates and friction plates are installed, apply transmission oil to the surfaces of each plate to avoid clutch plate seizure. ○ Install the friction plates and steel plates, starting with a friction plate and alternating them, finishing with a friction plate.
5-12 ENGINE RIGHT SIDE Clutch Spring Free Length Measurement • Since the spring [A] becomes shorter as it weakens, check its free length to determine its condition. If any of the springs is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 28.
ENGINE RIGHT SIDE 5-13 External Shift Mechanism External Shift Mechanism Remo val • Remove: Shift Pedal Right Engine Cover Clutch Housing • Remove the engine mounting bolt s [A] to pull out the ex- ternal shift mechanism. • Pull out the external shift mechanism [A], lifting the engine [B].
5-14 ENGINE RIGHT SIDE Primary Gear Primary Gear Removal • Remove the right engine cover (see Right Engine Cover Removal) • Remove the circlip [A], and take off the primary gear [B] and water pump drive gear .
ENGINE RIGHT SIDE 5-15 Primary Gear • Install the spring washer [A] with the concave side facing to the inward. • T emporarily tighten the primary gear nut [B]. • T ighten the primary gear nut ○ Primary gear nut is left-hand threads. T orque - Primary Gear Nut : 49 N·m (5.
5-16 ENGINE RIGHT SIDE Kickstarter Kickshaft Removal • Remove: Right Engine Cover (see Right Engine Cover Removal) Clutch Housing • Pull the end of the kick spring [ A] out of the hole in the crankcase. • Remove the ratchet guide bolt [B] and ratchet guide screw [C], take off the ratchet guide [D].
ENGINE REMOV AL/INST A LLA T ION 6-1 6 Engine Removal/Installation T able of Contents Exploded View ................................................................................................................... ..... 6-2 Engine Removal/Installation .
6-2 ENGINE REMOV AL/INST ALLA TION Exploded View 1. Frame 2. Pivot Shaft 3. Swingarm T1: 25 N·m (2.5 kgf·m, 18 ft·lb) 29 N·m (3.0 kgf·m, 21 ft·lb): KX65-A3 ∼ T2: 69 N·m (7.0 kgf·m, 51 ft·lb) G: Apply grease. L: Apply a non-permanent locking agent.
ENGINE REMOV AL/INST ALLA TION 6-3 Engine Removal/Installation Engine Removal • Drain the engine oil (se e Engine Bottom End/T ransmis- sion chapter).
6-4 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation Engine Installation • Install the engine on the frame. • Before tightening the engine mounting nuts, measure the left and right clearance [A] between the bosses [B] of crankcase and frame brackets [C] with thickness gauge.
ENGINE BOTT OM END/TRANSMISSION 7-1 7 Engine Bottom End/T ransmission T able of Contents Exploded View ................................................................................................................... ..... 7-2 Specifications .......
7-2 ENGINE BOTTOM END/TRANSMISSION Exploded View.
ENGINE BOTT OM END/TRANSMISSION 7-3 Exploded View 1. Crankshaft Assembly 2. Magneto Stator 3. Magneto Flywheel 4. Left Crankcase 5. Right Crankcase 6. Drive Shaft 7. Output Shaft 8. Engine Sprocket 9. Shift Rod 10. Shift Fork 1 1. Operating Plate 12. Shift Drum 13.
7-4 ENGINE BOTTOM END/TRANSMISSION Specifications Item Standard Service Limit T ransmission Oil: Engine Oil: Grade API SE, SF or SG ––– API SH, SJ or SL with JAS O MA Vis c o si t y SAE10W-40 ––– Capacity 0.5 L ––– Crankshaft, Connecting Rod Connecting Rod Bend Not more than 0.
ENGINE BOTTOM END/TRANSMISSION 7-5 T ransmission Oil In order for the transmission and clutch to function prop- erly , always maintain the transmission oil at the proper l evel and change the oil periodically .
7-6 ENGINE BOTTOM END/TRANSMISSION T ransmission Oil • Check the gasket at the engine oil drain plug for damage. Replace the gasket with a new one if it is damaged. • After the oil has completely drained out, install the engine oil drain plug with the gasket, and tighten it.
ENGINE BOTTOM END/TRANSMISSION 7-7 Crankcase Crankcase Splitting • Remove the engine (see the Engine Removal/Installation chapter). • Set the engine on a clean surface while parts are being removed.
7-8 ENGINE BOTTOM END/TRANSMISSION Crankcase • Pull out the shift rods [A]. • Disengage the shift fork guide pins from the shift drum grooves. • T ake off the shift drum [B] • Remove the shift forks [C] from the transmission gears. • T ake out the drive shaft [D] and output shaft [E] together with their gear meshed.
ENGINE BOTTOM END/TRANSMISSION 7-9 Crankcase • T urn the crankshaft [A] to BDC [B], and install the crank- shaft jig [C] between the flywheels opposite the connect- ing rod big end to protect flywheel alignment as shown. Install the suitable shaft [D] to the rear end of the crank- shaft jig.
7-10 ENGINE BOTT OM END/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the transmission shafts (see T ransmission Shaft Removal). • Using a press, remove the crankshaft from the right crankcase.
ENGINE BOTT OM END/TRANSMISSION 7-1 1 Crankshaft, Connecting Rod Connecting Rod Big End Radial Clearance Inspection • Set the crankshaft in a flywheel alig nment jig or on V blocks, and place a dial gauge against the connecting rod big end. • Push the connecting rod first towards the gauge and then in the opposite direction.
7-12 ENGINE BOTT OM END/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Alignment Inspection • In the case of horizontal misalignment, which is the most common, strike the projecting rim of the flywheel with a plastic, soft lead, or brass hammer as indicated in the figure.
ENGINE BOTTOM END/TRANSMISSION 7-13 T ransmission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Pull off the shift rods [A], and disengage the shift fork guide pins from the shift drum grooves. • Remove the shift drum [B] • Remove the shift forks [C] from the transmission gears.
7-14 ENGINE BOTT OM END/TRANSMISSION T ransmission • The output shaft gears can be identified by size; the largest diameter gear is 1st gear , and the smallest is 6th. Be sure that all parts are put back in the correct sequence and facing the proper direction, and that all circlips are properly in place.
ENGINE BOTTOM END/TRANSMISSION 7-15 T ransmission • Install the shift drum. • Fit the shift fork guide pins into the corresponding shift drum grooves. • Apply a little transmission oil to the shift rods, and slide them into the shift forks. • Holding the shift drum with the suitable tool and tighten the shift drum operating plate bolt.
7-16 ENGINE BOTT OM END/TRANSMISSION T ransmission Gear Damage Inspection • Visua lly inspect the gear teeth on the transmission gears. Repair lightly damaged gear teeth with an oilstone.
WHEELS/TIRES 8-1 8 Wheels/T ires T able of Contents Exploded View ................................................................................................................... ..... 8-2 Specifications ............................................
8-2 WHEELS/TIRES Exploded View 1. Nipple 2. Spoke 3. Front T ire 4. Rim 5. Front Axle 6. Swingarm 7. Rear T ire 8. Rear Axle T1: 1.5 N·m (0.15 kgf·m, 1 3 in·lb) T2: 79 N·m (8.0 kgf·m, 58 ft·lb) G: Apply Grease. R: Replacement Parts WL: Apply soap and water solution, or rubber lubricant.
WHEELS/TIRES 8-3 Specifications Item Standard Service Limit Wheels (Rims): Rim Size: Front 14 × 1.40 Rear 12 × 1.60 Rim Runout: Axial 1.0 mm or less 2m m Radial 1.0 mm or less 2m m Axle Runout/100 mm 0.1 mm 0.2 mm Tires Air Pressure Front and Rear 9 8k P a( 1 .
8-4 WHEELS/TIRES Wheels (Rims) Front Wheel R emoval • Using the jack [A] under the frame, and stabilize the mo- torcycle. Special T ool - Jack: 57001-1238 • Place a stand under the engine to raise the front wheel the ground. • Remove the cotter pin [A] • Unscrew the axle nut [B].
WHEELS/TIRES 8-5 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, i f the slots in the nut do not align with the cotter pin hole in the axle , tighten the nut clockwise [B] up to next alignment. ○ It should be within 30 degree.
8-6 WHEELS/TIRES Wheels (Rims) • Remove th e cotter p in [A]. • Remove the axle nut [B]. • P u l lo u tt h ea x l e[ C ] . • Move the rear wheel back with the rear caliper installed. • T ake off the collar and cap from the each side of the rear hub.
WHEELS/TIRES 8-7 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, i f the slots in the nut do not align with the cotter pin hole in the axle , tighten the nut clockwise [B] up to next alignment. ○ It should be within 30 degree.
8-8 WHEELS/TIRES Wheels (Rims) Rim Inspection • Remove the wheel, and support it with the tire by the a xle. • Measure the rim runout, axial [A] and radial [B], with a dial gauge. If the rim runout exceeds the service limit, check the hub bearings.
WHEELS/TIRES 8-9 Ti r es Air Pressure Inspection/Adjustment • Using tire air pressure gauge [A], measure the tire pres- sure when the tires are cold. Adjust the tire air pressure to suit tra ck conditions and rider preference, but do not stray too far from the recom- mended pressure.
8-10 WHEELS/TIRES Ti r es Tire R em o val CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground. • Remove the wheel from the motorcycle (see Wheels Re- moval).
WHEELS/TIRES 8-1 1 Ti r es Tire I ns ta lla ti on • Inspect the rim and tire, and replace them if necessary . • Install the tube. • Apply a soap and water solution, or rubber lubricant to the rim flange and tire beads.
8-12 WHEELS/TIRES Hub Bearings Hub Bearing Removal • Remove the wheel (see Wheel Removal). CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
WHEELS/TIRES 8-13 Hub Bearings • Replace the circlip and oil seals with new ones. • Press in the oil seals [A] so that the seal surface is flush [B] with the end of the hole.
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FINAL DRIVE 9-1 9 Final Drive T able of Contents Exploded View ................................................................................................................... ..... 9-2 Specifications ...............................................
9-2 FINAL DRIVE Exploded View 1. Engine Sprocket 2. Output Shaft 3. Swingarm 4. Chain Slipper 5. Chain G uide 6. Locknut 7. Adjusting Bolt 8. Chain Adjuster 9. Drive C hain 10. Rear Sprocket 1 1. Rear Axle 12. KX65-A6, A6F ∼ T1: 26 N·m (2.7 kgf·m, 20 ft·lb) T2: 79 N·m (8.
FINAL DRIVE 9-3 Specifications Item Standard Service Limit Drive Chain Chain Slack 44 ∼ 54 mm ––– 45 ∼ 55 mm (KX65-A3 ∼ ) ––– Chain 20-link Length 254.
9-4 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Support the motorcycle on its stand. • Check the wheel alignment (see Wheel Alignment Inspec- tion), and adjust it if necessary (see Wheel Alignment Ad- justment). NOTE ○ Clean the drive chain if it is dirty , and lubricate it if it appears dry .
FINAL DRIVE 9-5 Drive Chain • Bend the cotter pin [A] over the nut [B]. • Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary . WA R N I N G If the axle nut is not securely tightened, or the cotter pin is not installed, an unsafe riding condition may result.
9-6 FINAL DRIVE Drive Chain • Stretch the chain taut by hanging a 98 N (10 kg, 20 lb) weight [A] on the chain. • Measure the length of 20 links [B] on the straight part [C] of the chain from the pin center of the 1st pin to the pin center of the 21st pin.
FINAL DRIVE 9-7 Drive Chain Drive Chain Installatio n • Fit the drive chain back onto the sprockets with the ends at the rear sprocket. • Install the master link from the frame side. • Install the clip [A] so that the closed end of the "U" [B] points in the direction of chain rotation [C].
9-8 FINAL DRIVE Sprockets Engine Sprocket Remo val • Remove: Magneto Cover Drive Chain [A] (free of engine sprocket) • Remove the circlip [B], and pull off the engine sprocket [C]. Special T ool - Outside Circlip Pliers: 57001-144 Engine Sprocket Installation • Replace the circlip with a new one.
FINAL DRIVE 9-9 Sprockets Rear Sprocket Warp Inspection • Using the jack, raise the rear wheel off the ground. Special T ool - Jack: 57001-1238 • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown and rotate [C] the rear wheel to measure the sprocket runout (warp).
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BRAKES 10-1 10 Brakes T able of Contents Exploded View ................................................................................................................... ..... 10-2 Specifications ......................................................
10-2 BRAKES Exploded View 1. Front Brake Reservoir 2. Brake Lever 3. Brake Hose 4. Clamps 5. Front Caliper 6. Brake Pad 7. Piston 8. Front Disc T1: 25 N·m (2.5 kgf·m, 18 ft·lb) T2: 8.8 N ·m (0.90 kgf·m, 78 in·lb) T3: 7.8 N ·m (0.80 kgf·m, 69 in·lb) T4: 18 N·m (1.
BRAKES 10-3 Exploded View 1. Rear Brake Reservoir 2. Rear Master Cylinder 3. Brake Hose 4. Brake Pedal 5. Rear Caliper Cover 6. Rear Caliper 7. Piston 8. Brake Pad 9. Rear Disc T1: 25 N·m (2.5 kgf·m, 18 ft·lb) T2: 9.8 N·m (1.0 kgf·m, 87 in·lb) T3: 7.
10-4 BRAKES Specifications Item Standard Service Limit Brake Adjustment Lever Play Adjustable (to suit rider) ––– Brake Fluid Recommended Disc Brake Fluid: ––– Ty p e DOT3 or DOT4 ––– Brake Pads Lining Thickness: Front 4.5 mm 0.7 mm Rear 4.
BRAKES 10-5 Brake Lever , Brake Pedal Brake Lever Pl ay Adjustment • Adjust the front brake lever [A] to suit you. • Slide the brake lever dust cover [B] out of place. • Loosen the adjuster locknut [C] and turn the adjuster [D] to either side. • After adjustment, tighten the locknut.
10-6 BRAKES Brake Lever , Brake Pedal • Remove the brake pedal mounting bolt [A] and take off the brake pedal and return spring [B]. Brake Pedal Installation • Check the pedal O-ring for signs of damage.
BRAKES 10-7 Brake Fluid WA R N I N G When working with the disc brake, observe the pre- cautions listed below . 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use i n the brake.
10-8 BRAKES Brake Fluid Fluid Level Inspection In accordance with the Periodic Maintenance Chart, in- spect the brake fluid level in the front and rear brake fluid reservoirs. • Check the brake fluid level in the front brake reservoir [A]. NOTE ○ Hold the reservoir horizontal when checking brake fluid level.
BRAKES 10-9 Brake Fluid NOTE ○ The procedure to change the front brake fluid is as fol- lows. Changing the rear brake fluid is the same as for the front br ake. • Level the brake fluid reservoir . • Remove the reservoir cap. • Remove the rubber cap [A] on the bleed valve [B].
10-10 BRAKES Brake Fluid Bleeding the Brake Line The brake fluid has a very low compression c oefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air , however , is easily compressed.
BRAKES 10-1 1 Brake Fluid • Remove the clear plastic hose. • T ighten the bleed valves, and install the rubber cap. T orque - Cal iper Bleed V alve: 7.8 N·m (0.8 kgf·m, 69 in·l b) • Check the fluid level. • After bleeding is done, check the brake for good braking power , no brake drag, and no fluid leakage.
10-12 BRAKES Caliper Caliper Removal Front Brake • Loosen the banjo bolt [A] so as not to spill brake fluid. • Remove the caliper mounting bolts [B].
BRAKES 10-13 Caliper Caliper Disassembly • Remove the front/rear caliper (see Caliper removal). • Remove the pads and spring (see Pad Removal). • Remove the caliper holder , shaft rubber friction boot and cover . • Using compressed air , remove the piston(s).
10-14 BRAKES Caliper • Install the anti-rattle spring [A] in the caliper as shown. • Replace the shaft rubber boot and dust cover if they are damaged. • Apply a thin coat of silicone grease to the caliper holder shafts and holder holes (PBC is a special high tempera- ture, water-resistant grease).
BRAKES 10-15 Caliper Brake Pad Removal • Loosen the pad bolts [A]. • Remove the caliper [B]. • Remove the pad bolts. • T ake out the piston side pad. • Push the caliper holder toward the piston, and then re- move another pad from the calip er holder .
10-16 BRAKES Master Cylinder CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately . Front Mast er Cylinder Rem oval • Remove the banjo bolt [A] to disconnect the upper brake hose from the master cylinder (see Brake Hose Re- moval/Installation).
BRAKES 10-17 Master Cylinder Rear Master Cylinder Removal • Remove the right side cover and the reservoir mounting bolt [A]. • Remove the cotter pin [B]. • Pull off the joint pin [C] with washer . NOTE ○ Pull off the joint pin while pressing down the brake pedal.
10-18 BRAKES Master Cylinder Rear Master Cylinder Disassembly • Remove the rear master cylinder . • Slide the dust cover [A] on the push rod [B] out of place, and remove the retainer [C]. Special T ool - Inside Circlip Pliers: 57001-143 • Pull out the push rod with the piston stop [D].
BRAKES 10-19 Master Cylinder Master Cylinder Inspection (Visual Inspection) • Disassemble the front and rear master cylinders. • Check that there are no scratches, rust or pitting on the inner wall of each master cylinder [A] and on the outside of each piston [B].
10-20 BRAKES Brake Disk Brake Disc Inspection • Visually inspect the disc [A]. If it is scratched or damaged, replace the disc. • Measure the thickness of each disc at the point [B] where it has worn the most. Replace the disc if it has worn past the service limit.
BRAKES 10-21 Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with watered cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
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SUSPENSION 1 1-1 11 Suspension T able of Contents Exploded View ................................................................................................................... ..... 1 1-2 Specifications ............................................
1 1-2 SUSPENSION Exploded View.
SUSPENSION 1 1-3 Exploded View 1. T op Plug 2. O-ring 3. Fork Spring 4. Piston Cylinder Unit 5. Inner T ube 6. Guide Bushes 7. Dust Seal 8. Retaining Ring 9. Oil Seal 10. W asher 1 1. Outer Tube 12. Gasket 13. Allen Bolt 14. Steering Stem Head 15. Steering Stem 16.
1 1-4 SUSPENSION Exploded View.
SUSPENSION 1 1-5 Exploded View 1. Pivot Shaft 2. Swingarm 3. Rocker Arm 4. T ie-rod 5. Rear Shock Absorber 6. Rear Shock Absorber (KX65-A3 ∼ ) T1: 69 N·m (7.0 kgf·m, 51 ft·lb) T2: 83 N·m (8.5 kgf·m, 61 ft·lb) T3: 59 N·m (6.0 kgf·m, 43 ft·lb) T4: 34 N·m (3.
1 1-6 SUSPENSION Specifications Item Standard Service Limit Front Fork Oil SHOW A SS-8 or equivalent ––– Oil Capacity (Completely Dry) 238 ±2.5 mL (KX65-A1) ––– 240 ±2.
SUSPENSION 1 1-7 Front Fork The front fork should always be adjusted for the rider’s weight and track conditions by using one or more of the following methods. ○ Oil level adjustment - The effects of higher or lower fork oil level are only felt during the final 100 mm of fork travel.
1 1-8 SUSPENSION Front Fork KX65-A3 ∼ • Remove: Number Plate Handlebar Assembly Front Fork T op Plug [A] Fork Spring [B] Fork Spring Seat [C] • Slowly compress the front fork fully by pushing up the outer tubes [A] using a jack or other suitable means under the front wheel.
SUSPENSION 1 1-9 Front Fork • Check both top plug O-ring [A] for damage and replace them if necessary . • Install the fork top plug. • Install the fork top plug and fork spring seat (KX65-A3 ∼ ). • T ighten the fork top plug. T orque - Front Fork T op Plug: 22 N·m (2.
1 1-10 SUSPENSION Front Fork • Adjust the oil level. ○ With the fork fully compressed, put the oil level gauge [A] and the stopper [B], and inspect the dista nce from the top of the inner tube to the oil.
SUSPENSION 1 1-1 1 Front Fork Front Fork Installation • If the fork leg was disassembled, check the fork oil level. • Install the fork so that the top end [A] of the inner tube is 10 mm up [B] with the upper surface [C] of the steering stem head.
1 1-12 SUSPENSION Front Fork • Remove the cylinder unit [A] and spring [B] from the fork. • Remove the dust seal [A] and retaining ring [B]. • Use the fork outer tube weight [A] to separate the inner tube from the outer tube.
SUSPENSION 1 1-13 Front Fork Front Fork Assembly (each fork) • Assembly is the reverse of disassembly . • Replace the following parts removed with a new one . Guide Bushes Oil Seal Bottom Allen Bolt Gasket • Inspect the following and replace them with new ones if damaged.
1 1-14 SUSPENSION Front Fork Inner T ube Inspection • Visually inspect the inner tube [A], repair any damage. • Nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas wh ich cause seal damage. If the damage is not repairable, replace the inner tube.
SUSPENSION 1 1-15 Rear Suspension (Uni-T rak) Rear Shock Absorber The rear suspension system of this motorcycle is Uni-trak. It consists of a rear shock absorber , swingarm, tie-rod and rocker arm. T o suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one.
1 1-16 SUSPENSION Rear Suspension (Uni-T rak) • Using the hook wrench [A], turn the adjusting nut [B] as required. Tu rning the adjusting nut downward marks the spring action harder and upward softer .
SUSPENSION 1 1-17 Rear Suspension (Uni-T rak) • Remove the rear shock absorber upper mounting bolt [A], and pull out the rear shock absorber [B]. Rear Shock Absorber Installation • Pack the rocker arm needle bearings with grease. • T ighten the following: T orque - Rear Shock Absorber Mounting Bolt (Upper): 39 N·m (4.
1 1-18 SUSPENSION Rear Suspension (Uni-T rak) • Remove the rear shock absorber from the vise. • Remove the stopper ring [A]. • Remove the spring seat [B] from the shock absorber and lift off the spring [C]. • Install the spring guide. • Adjust the spring preload (see Spring Preload Adjust- ment).
SUSPENSION 1 1-19 Swingarm Swingarm Removal • Place the jack under the frame so that the rear wheel is off the ground. Special T ool - Jack: 57001-1238 • Remove the rear wheel (see Wheels/T ires chapter). • Remove the brake pedal [A]. • Remove the tie-rod rear mounting bolt [B].
1 1-20 SUSPENSION Swingarm Swingarm Bearing Installation • Replace the needle bearings, dust seals and oil seals with new ones. • Apply plenty of grease to the dust seals, oil seals and needle bearings. NOTE ○ Install the needle bearings so that the manufacturer ’s marks face out.
SUSPENSION 1 1-21 T ie-rod, Rocker Arm Tie-rod Removal • Using the jack under the frame, raise the rear wheel off the ground. Special T ool - Jack: 57001-1238 • Remove the tie-rod front mounting bolt [A]. CAUTION When pulling out the mounting bolts, lift the rear wheel slightly .
1 1-22 SUSPENSION T ie-rod, Rocker Arm Rocker Arm Installation • Apply plenty of grease to the inside of the rocker arm holes, needle bearings, oil seals and grease seals out- side of the sleeve. • Install the needle bearing [A], grease seals [B] and oil seals [C] position as shown.
SUSPENSION 1 1-23 Uni-T rak Maintenance Check the uni-trak component parts for wear periodically , or whenever excessive play is suspected. • Using the jack under the frame, raise the rear wheel off the ground. Special T ool - Jack: 57001-1238 • Push and pull on the swingarm [A], up an d down, to check for wear .
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STEERING 12-1 12 Steering T able of Contents Exploded View ................................................................................................................... ..... 12-2 Specifications ..................................................
12-2 STEERI NG Exploded View 1. Handlebar Clamp 2. Handlebar 3. Steering Stem Head Nut 4. Steering Stem Head Bracket 5. Steerin g S tem Nut 6. T apered Roller Bearing 7. Head Pipe 8. T apered Roller Bearing 9. Steering Stem T1: 44 N·m (4.5 kgf·m, 33 ft·lb) T2: 20 N·m (2.
STEERING 12-3 Specifications Special T ools - Steering Stem Bearing Driver: 57001-137 Head Pipe Outer Race Press Shaf t: 57001-1075 Steering Stem Bearing Dri ver Adapter: 57001-1092 Steering Stem Nut .
12-4 STEERI NG Steering Steering Inspection • Using the jack, raise the front wheel off the ground. Special T ool - Jack: 57001-1238 • With the front wheel pointing straight ahead, alternately nudge each end of the handlebar . The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
STEERING 12-5 Steering Steering Stem, Stem Bearing Removal • Remove: Front Wheel (see Wheels/T ires c hapter) Brake Hose Clamp (see Brake System chapter) Caliper Mounting Bolts (see Brake System cha.
12-6 STEERI NG Steering Steering Stem, Stem Bearing Installation • Replace the bearing outer race with new ones. ○ Apply grease to the outer races, and drive them into the head pipe using the press shaft [A] and the drivers [B].
STEERING 12-7 Steering T orque - Steering Stem Head Nut : 44 N·m (4.5 kgf ·m, 33 ft·lb) Front Fork Clamp Bolt : Upper: 20 N·m (2.0 kgf·m, 1 5 ft·lb) Lower: 29 N·m (3.0 kgf·m , 22 ft·lb ) • Install the parts removed (see t he appropriate chapter).
12-8 STEERI NG Steering Maintenance Stem Bearing Lubrication • Remove the steering stem (see Steering Stem Removal). • Using a high flash-point solvent, wash the upper and lower tapered rollers in the cages, and wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean off grease and dirt.
STEERING 12-9 Handlebar Handlebar Removal • Remove: Engine Stop Button [A] Clutch Holder [B] Throttle Grip Assembly [C] Front Master Cylinder [D] Handlebar Holders [E] Handlebar [F] Handlebar Installation • Apply adhesive cement to the inside of the left handlebar grip [A].
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ELECTRICAL SYSTEM 13-1 13 Electrical System T able of Contents Wiring Diagram .................................................................................................................. ..... 13-2 Exploded View .................................
13-2 ELECTRICAL SYSTEM Wiring Diagram KX65A6F ∼.
ELECTRICAL SYSTEM 13-3 Exploded View 1. Magneto Cover 2. Magneto Flywheel 3. Stator 4. CDI Unit 5. Ignition Coil 6. Spark Plug Cap 7. Spark Plug 8. Engine Stop Button 9. KX65-A1 ∼ A6 T1: 29 N·m (3.0 k gf·m, 21 ft·lb) T2: 4.9 N ·m (0.50 kgf·m, 43 in·lb) T3: 25 N·m (2.
13-4 ELECTRICAL SYSTEM Specifications Item Standard Magneto Stator coil resistance in the text Ignition System Ignition T iming: 20.5° BTDC @6 000 r/min (rpm) 20.5° BTDC @7 100 r/min (rpm) (KX65A6F ∼ ) Ignition Coil: 3 Needle Arcing Distance 7m mo rm o r e Primary Winding Resi stance 0.
ELECTRICAL SYSTEM 13-5 Precautions There are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below . ○ The electrical parts should never be struck sharply , as with a hammer , or allowed to fall on a hard surface.
13-6 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor , replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.
ELECTRICAL SYSTEM 13-7 Ignition Timing Ignition Timing Adjustment • Remove the magneto cover . • Check to see if the center mark of the three marks [A] on the magneto stator plate is aligned with the mark [B] on the crankcase. If the marks are not aligned, loosen the magneto stator plate mounting screws [C] and turn the s tator [D].
13-8 ELECTRICAL SYSTEM Flywheel Magneto Flywheel Magneto Removal • Remove the magneto cover . • Hold the flywheel steady , with the flywheel & pulley holder [A], and remove the flywheel nut [B].
ELECTRICAL SYSTEM 13-9 Flywheel Magneto • Using a high flash-point solvent, clean off any oil or dirt that may be on the crankshaft ta per [A] or in the hole [B] in the flywheel. Dry them with a clean cloth. • Fit the woodruff k ey [A] securely in the slot in the crank- shaft before installing the stator plate.
13-10 ELECTRICAL SYSTEM Flywheel Magneto • T o check the stator coil resistance as follows. ○ Connect the hand tester to the terminals of the harn ess connector [A] as shown in the table 2.
ELECTRICAL SYSTEM 13-1 1 Ignition System Safety Instructions WA R N I N G The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil, or high tension lead while the engine is running, or you could receive a severe electrical shock.
13-12 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection (KX65A6F ∼ ) • Disconnect the magneto lead connector [C]. • Set the hand tester [B] to the × 25 V DC range, and con- nect it a commercially available Peak volta ge adapter [A] as shown in the diagram.
ELECTRICAL SYSTEM 13-13 Ignition System WA R N I N G T o avoid extremely high voltage shocks, do not touch the coil or lead. If the distance reading is less than the specified value, the ignition coil or spark plug cap is defective.
13-14 ELECTRICAL SYSTEM Ignition System Spark Plug Clea ning and Inspec tion • Remove the spark plug, and visually inspect it. • Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high flash-point solvent and a w ire brush or other suitable tool.
ELECTRICAL SYSTEM 13-15 Ignition System Ignition Coil Primary Peak V oltage Check • Remove: Shrouds Side Covers Seat Fuel T ank • Disconnect the spark plug cap from the spark plug [A]. • Connect the new spark plug [B] to the spark plug cap, then ground it to the engine.
13-16 ELECTRICAL SYSTEM Ignition System.
ELECTRICAL SYSTEM 13-17 Ignition System Exciter (Stator) Coil Peak V oltage Check • Disconnect the connector of the harness from the CDI Unit. • T o check the peak voltage, do the following procedures. NOTE ○ Measure the voltage with each lead connected cor - rectly .
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APPENDIX 14-1 14 Appendix T able of Contents T roubleshooting Guide ........................................................................................................... 14-2 General Lubrication ..................................................
14-2 APPENDIX T roubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
APPENDIX 14-3 T roubleshooting Guide Flywheel magneto damaged Ignition coil lead or CDI Unit lead not in good contact Fuel/air mixture incorrect: Main jet clogged or wrong size Jet needle or needle je.
14-4 APPENDIX T roubleshooting Guide Jumps out of gear: Shift fork worn Gear groove worn Gear dogs and/or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro- ken Shift for.
APPENDIX 14-5 T roubleshooting Guide Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Steering stem bent Front fork leg bent Right/left front fork.
14-6 APPENDIX General Lubrication Lubrication (Periodic Maintenance) • Before lubricating each part, clean off any rusty spots with rust remover and wipe of f any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant.
APPENDIX 14-7 Nut, Bolt, and Fastener T ightness Tightness Inspection • Check the tightness of bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at room temperature).
14-8 APPENDIX Unit Conversion T able Prefixes for Units: Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units of Mass: kg × 2.205 = lb g × 0.03527 = oz Units of V olume: L × 0.2642 = gal (US) L × 0.
MODEL APPLICA TION Ye a r Model Beginning Frame No. 2000 KX65-A1 JKBKEAC □ Y A000001 or JKAKX065AAA000001 2001 KX65-A2 JKBKXEAC □ 1A009001 or JKBKX065AAA009001 2002 KX65-A3 JKBKXEAC □ 2A016001 o.
An important point after buying a device Kawasaki KX65 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kawasaki KX65 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kawasaki KX65 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kawasaki KX65 you will learn all the available features of the product, as well as information on its operation. The information that you get Kawasaki KX65 will certainly help you make a decision on the purchase.
If you already are a holder of Kawasaki KX65, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kawasaki KX65.
However, one of the most important roles played by the user manual is to help in solving problems with Kawasaki KX65. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kawasaki KX65 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
