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KX65
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki KX65

   Summary of Contents for Kawasaki KX65

  • Page 1 KX65 Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Fuel System Cooling System Engine Top End Engine Right Side Engine Removal/Installation Engine Bottom End/Transmission 7 j Wheels/Tires Final Drive Brakes 10 j Suspension 11 j Steering 12 j Electrical System 13 j Appendix 14 j This quick reference guide will assist you in locating a desired topic or pro- cedure.
  • Page 5 All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 1999 Kawasaki Heavy Industries, Ltd. 12th Edition (1) : Mar. 1, 2010...
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: How To Use This Manual

    Be alert for problems and non-scheduled which will help you distinguish different types maintenance. • of information. Use proper tools and genuine Kawasaki mo- torcycle parts. Special tools, gauges, and NOTE ○ testers that are necessary when servicing This note symbol indicates points of par-...
  • Page 9: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Periodic Maintenance Chart ....................Torque and Locking Agent...................... 1-11 Special Tools and Sealants ....................1-14 Cable, Wire and Hose Routing ....................1-18...
  • Page 10: General Information

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 11: General Information

    GENERAL INFORMATION 1-3 Before Servicing (11) 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.
  • Page 12: Before Servicing

    1-4 GENERAL INFORMATION Before Servicing (19)Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent...
  • Page 13: Left/right Side View

    GENERAL INFORMATION 1-5 Model Identification KX65-A1 Left Side View KX65-A1 Right Side View...
  • Page 14: General Specifications

    KX65-A1 ∼ A2 Items ∼ ABF Dimensions Overall Length 1 580 mm 1 590 mm Overall Width 690 mm (KX65-A1), 730 mm (KX65-A2) 760 mm Overall Height 925 mm (KX65-A1), 935 mm (KX65-A2) 955 mm Wheelbase 1 110 mm 1 120 mm...
  • Page 15 GENERAL INFORMATION 1-7 General Specifications KX65-A3 ∼ A6, A6F KX65-A1 ∼ A2 Items ∼ ABF Drive Train Primary Reduction System: Type Gear ← Reduction Ratio 3.500 (77/22) ← Clutch Type Wet, multi disc ← Transmission: Type 6-speed, constant mesh, return shift ←...
  • Page 16: General Specifications

    1-8 GENERAL INFORMATION General Specifications KX65-A3 ∼ A6, A6F KX65-A1 ∼ A2 Items ∼ ABF Brake Type: Front and Rear Single disc ← Effective Disc Diameter: Front 154.8 mm ← Rear 146 mm ← Specifications are subject to change without notice, and may not apply to every country.
  • Page 17: Periodic Maintenance Chart

    GENERAL INFORMATION 1-9 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQUENCY After Every Every Every each 3 races 5 races 10 races race (or (or 7.5 (or 12.5 (or 25 required...
  • Page 18 1-10 GENERAL INFORMATION Periodic Maintenance Chart FREQUENCY After Every Every Every each 3 races 5 races 10 races race (or (or 7.5 (or 12.5 (or 25 required OPERATION 2.5 hr.) hr.) hr.) hr.) • Fuel hoses, connections - inspect † •...
  • Page 19: Torque And Locking Agent

    GENERAL INFORMATION 1-11 Torque and Locking Agent Tighten 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. The following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.
  • Page 20: Fastener

    1-12 GENERAL INFORMATION Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Removal/Installation Engine Mounting Nuts Engine Mounting Nuts (KX65-A3 ∼) Swing Arm Pivot Shaft Nut Engine Bottom End/Transmission Cylinder Stud – – – L (Planted Side) Crankcase Bolts 0.90...
  • Page 21: Torque And Locking Agent

    GENERAL INFORMATION 1-13 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Rocker Arm Pivot Nut Caliper Mounting Bolts Rear Frame Mounting Bolts Steering Steering Stem Head Nut Steering Stem Nut 0.30 26 in·lb Handlebar Clamp Bolts Clutch Lever Clamp Bolts 0.90 78 in·lb Front Fork Clamp Bolts (Upper)
  • Page 22: Special Tools And Sealants

    1-14 GENERAL INFORMATION Special Tools and Sealants Bearing Puller Adapter: Fork Cylinder Holder Handle: 57001-136 57001-183 Steering Stem Bearing Driver: Flywheel Puller, M12 × 1.75: 57001-137 57001-252 Inside Circlip Pliers: Piston Pin Puller Assembly: 57001-143 57001-910 Outside Circlip Pliers: Fork Cylinder Holder Adapter: 57001-144 57001-1011 Bearing Puller:...
  • Page 23 GENERAL INFORMATION 1-15 Special Tools and Sealants Rim Protector: Hook Wrench R37.5, R42: 57001-1063 57001-1101 Bead Breaker Assembly: Head Pipe Outer Race Driver, 46.5: 57001-1072 57001-1106 Head Pipe Outer Race Press Shaft: Head Pipe Outer Race Remover ID > 37 mm: 57001-1075 57001-1107 Steering Stem Bearing Driver Adapter, 29.7:...
  • Page 24 1-16 GENERAL INFORMATION Special Tools and Sealants Front Fork Oil Seal Driver: Peak Voltage Adapter: 57001-1219 57001-1415 Jack: Crank Shaft Jig: 57001-1238 57001-1439 Fork Oil Level Gauge: Graduated Cylinder & Tube: 57001-1290 57001-1584 Crankcase Splitting Tool Assembly: Flywheel & Pulley Holder: 57001-1362 57001-1605 Hand Tester:...
  • Page 25 GENERAL INFORMATION 1-17 Special Tools and Sealants Liquid Gasket, TB1211: Liquid Gasket, TB1105B: 56019-120 92104-002...
  • Page 26: Cable, Wire And Hose Routing

    13. Install the kick pedal so that it should be the air vent hose, the overflow hose and parallel to the frame as shown in figure. 14. KX65-A1 ∼ A2 the breather hose as shown in figure. 7. CDI Unit (KX65-A1 ∼ A6) 15. KX65-A3 ∼ A6...
  • Page 27 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.) 8.
  • Page 28 1-20 GENERAL INFORMATION 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.
  • Page 29 GENERAL INFORMATION 1-21 Cable, Wire and Hose Routing 1. Front Brake Reservoir 2. Banjo Bolts 3. Clamp 4. Front Brake Disk 5. Bleed Valves 6. Front Brake Caliper 7. Rear Brake Caliper 8. Rear Brake Disk 9. Rear Brake Reservoir 10.
  • Page 30 1-22 GENERAL INFORMATION Cable, Wire and Hose Routing KX65A6F ∼ 1. Throttle Cable 9. Ignition Coil Primary Lead 10. Ignition Coil Ground Lead 2. Clutch Cable 3. Band 11. Ignition Coil 4. Engine Stop Button Lead 12. Band 5. Clamp 13.
  • Page 31 FUEL SYSTEM 2-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Throttle Grip and Cable ......................Free Play Inspection ......................Free Play Adjustment......................Throttle Cable Installation ....................Cable Lubrication ......................Cable Inspection ....................... Carburetor ..........................Idle Speed Inspection ....................... Idle Speed Adjustment......................
  • Page 32: Exploded View

    2-2 FUEL SYSTEM Exploded View 1. Throttle Cable 13. Air Screw 2. Throttle Grip 14. Slow Jet 3. Carburetor Holder 15. Float Valve Needle 4. Carburetor Cap 16. Main Jet 5. Spring 17. Float 6. Retainer 18. Reed Valve 7. Jet Needle Clip T1: 8.8 N·m (0.90 kgf·m, 78 in·lb) 8.
  • Page 33 FUEL SYSTEM 2-3 Exploded View 1. Fuel Tank Cap 2. Fuel Tank 3. Fuel Tap 4. Air Cleaner Housing 5. Element 6. Frame 7. Holder 8. Air Cleaner Duct 9. KX65A6F ∼ 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.
  • Page 34: Specifications

    2-4 FUEL SYSTEM Specifications Standard Service Item Limit KX65-A1 ∼ A2 KX65-A3 ∼ Throttle Grip Free Play and Cable 2 ∼ 3 mm ← – – – Carburetor Make/Type MIKUNI VM24SS ← – – – Main Jet #230 #190 – – –...
  • Page 35: Throttle Grip And Cable

    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. Also, the throttle valve may not open fully at full throttle. On the other hand, if the throttle grip has no play, the throttle will be hard to control, and the idle speed will be erratic.
  • Page 36: Throttle Cable Installation

    2-6 FUEL SYSTEM Throttle Grip and Cable Throttle Cable Installation • Install the throttle cable in accordance with the Cable, Wire and Hose Routing section in the General Informa- tion chapter. • After the installation, adjust each cable properly. WARNING Operation with incorrectly routed or improperly ad- justed cables could result in an unsafe riding con- dition.
  • Page 37: Carburetor

    Idle Speed Adjustment • First turn in the air screw [A] until it seats lightly, and back it out 2 turns (KX65-A1 ∼ A2). • First turn in the air screw [A] until it seats lightly, and back out 1 1/2 turns (KX65-A3 ∼).
  • Page 38: Service Fuel Level Adjustment

    2-8 FUEL SYSTEM 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.
  • Page 39: Carburetor Removal

    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 height lowers the fuel level and decreasing the float height raises the fuel level. Float Height Standard: 21.1 ±1 mm...
  • Page 40: Carburetor Installation

    2-10 FUEL SYSTEM Carburetor • Unscrew the carburetor cap [A], and pull out the throttle valve assembly [B]. NOTICE If the throttle valve is left attached to the cable, wrap it in a clean cloth to avoid damage. • After removing the carburetor, push a clean, lint-free towel into the carburetor holder and the air cleaner duct to keep dirt or other foreign material from entering.
  • Page 41: Fuel Inspection

    FUEL SYSTEM 2-11 Carburetor • Turn the fuel tap to the ON position, and check for fuel leakage from the carburetor. WARNING Fuel spilled from the carburetor is hazardous. • Adjust the following items if necessary: Throttle Cable (see this chapter) Idle Speed (see this chapter) Fuel Inspection WARNING...
  • Page 42: Carburetor Assembly

    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]. • Disassemble the carburetor body. Choke Plunger Assembly [A] (unscrew) Idle Adjusting Screw, Spring and O-ring [B] (unscrew) Air Screw and Spring [C] (unscrew) •...
  • Page 43: Carburetor Cleaning

    FUEL SYSTEM 2-13 Carburetor Carburetor Cleaning WARNING Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the carburetor in a well ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light.
  • Page 44 2-14 FUEL SYSTEM Carburetor • Remove the carburetor. • Before disassembling the carburetor, check the fuel level (see Fuel Level Inspection). If the fuel level is incorrect, inspect the rest of the carbu- retor before correcting it. • Pull the carburetor cable to check that the throttle valve [A] moves smoothly and returns by spring pressure.
  • Page 45: Rear Frame Mounting Bolts

    FUEL SYSTEM 2-15 Air Cleaner Air Cleaner Housing Removal • 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]. •...
  • Page 46: Element Cleaning And Inspection

    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 Inspection NOTE ○ In dusty areas, the element should be cleaned more frequently than recommended interval. ○...
  • Page 47: Fuel Tank

    FUEL SYSTEM 2-17 Fuel Tank Fuel Tank Removal WARNING 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;...
  • Page 48: Fuel Tap Inspection

    2-18 FUEL SYSTEM Fuel Tank Fuel Tap Inspection • 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.
  • Page 49: Reed Valve

    FUEL SYSTEM 2-19 Reed Valve Reed Valve Removal • Remove the carburetor holder mounting bolts and carbu- retor holder [A]. • Remove the reed valve [B] out of the cylinder. Reed Valve Installation • When the reed or stop are replaced, install the reed [A] and stop [B] onto the reed valve holder [C], aligning the chamfered corner [D] of the reed with that of the reed stop.
  • Page 50: Fuel Hose

    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. Remove the fuel tank and check the fuel hose.
  • Page 51 COOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View........................Specifications ......................... Coolant ........................... Coolant Level Inspection....................Coolant Deterioration Inspection..................Coolant Draining ....................... Coolant Filling ........................Air Bleeding........................Cooling System Pressure Testing ..................Cooling System Flushing ....................Disassembly and Assembly Precautions................Water Pump..........................
  • Page 52: Exploded View

    3-2 COOLING SYSTEM Exploded View 1. Radiator 11. Cylinder Head 2. Radiator Cap 12. Cylinder 3. Water Pump Cover 13. Air Bleeder Bolt 4. Drain Plug T1: 8.8 N·m (0.90 kgf·m, 78 in·lb) 5. Impeller T2: 8.3 N·m (0.85 kgf·m, 73 in·lb) 6.
  • Page 53: Specifications

    COOLING SYSTEM 3-3 Specifications Item Standard Coolant Type Permanent type antifreeze for aluminum engines and radiators Color Green Mixed ratio Soft water 50%, coolant 50% Total amount 0.4 L Radiator 108 ∼ 137 kPa (1.1 ∼ 1.4 kgf/cm², 16 ∼ 20 psi) Cap relief pressure Special Tools - Bearing Driver Set: 57001-1129 Outside Circlip Pliers: 57001-144...
  • Page 54: Coolant

    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). WARNING Hot engine coolant can cause serious burns. To avoid burns, do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot.
  • Page 55: Coolant Draining

    COOLING SYSTEM 3-5 Coolant Coolant Draining The coolant should be changed periodically to ensure long engine life. WARNING Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot;...
  • Page 56: Air Bleeding

    3-6 COOLING SYSTEM Coolant • 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. NOTE ○ Pour in the coolant slowly so that it can expel the air from the engine and radiator.
  • Page 57: Cooling System Flushing

    COOLING SYSTEM 3-7 Coolant 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 cool- ing system. If this accumulation is not removed, it will clog up the water passages and considerably reduce the effi- ciency of the cooling system.
  • Page 58: Disassembly And Assembly Precautions

    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 the system with coolant, bleed any air from the system.
  • Page 59: Water Pump

    COOLING SYSTEM 3-9 Water Pump Water Pump Cover Removal • Drain the coolant (see Coolant Draining). • Loosen the water hose clamps [A], and disconnect the water hoses on the water pump cover [B]. • Unscrew the cover bolts [C], and remove the water pump cover.
  • Page 60: Water Pump Shaft Removal

    3-10 COOLING SYSTEM Water Pump Water Pump Shaft Removal • Remove: Right Engine Cover (see Engine Right Side chapter) • Remove the circlip [A], and pull off the primary gear [B]. Special Tool - Outside Circlip Pliers: 57001-144 KX65A6F ∼: •...
  • Page 61 COOLING SYSTEM 3-11 Water Pump • Press the ball bearing [A] into the hole until the bearing is bottomed against the step [B]. Special Tools - Bearing Driver Set: 57001-1129 • Apply plenty of high temperature grease to the oil seal lips [D].
  • Page 62: Radiator Mounting Bolts

    3-12 COOLING SYSTEM Radiator Radiator Removal • Drain the coolant (see Coolant Draining). • Remove: Left Shroud [A] Water Hose [B] Radiator Mounting Bolts [C] Radiator Screen [D] Breather Hose Radiator [E] Radiator Installation • Radiator installation is the reverse of removal. •...
  • Page 63: Cap Inspection

    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.
  • Page 65 ENGINE TOP END 4-1 Engine Top End Table of Contents Exploded View........................Specifications ......................... Cylinder Head......................... Cylinder Compression Measurement................Cylinder Head Removal ....................Cylinder Head Installation ....................Cylinder Head Warp Inspection ..................Cylinder ..........................Cylinder Removal......................Cylinder Installation......................Piston Removal......................... Piston Installation......................
  • Page 66: Exploded View

    4-2 ENGINE TOP END Exploded View 1. Spark Plug 12. Gasket 13. Muffler Body (KX65-A1 ∼ A2) 2. Cylinder Head 3. Cylinder T1: 25 N·m (2.5 kgf·m, 18 ft·lb) 4. Piston Ring T2: 5.9 N·m (0.60 kgf·m, 52 in·lb) 5. "1N" Mark T3: 26 N·m (2.6 kgf·m, 19 ft·lb)
  • Page 67: Specifications

    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, Piston 44.500 ∼...
  • Page 68: Spark Plug

    ○ Use a compression gauge commercially available. It’s impossible to install as the frame will interfere with the operation if using KAWASAKI special tools (PN: 57001 -221 & 57001-1159). • With the throttle fully open, turn the engine over sharply...
  • Page 69: Cylinder Head Installation

    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.
  • Page 70: Cylinder

    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) Water Hose Upper End Clutch Cable Lower End Muffler Holding Springs • Remove the cylinder nuts [A]. •...
  • Page 71: Piston Installation

    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 the piston, then lightly polish the piston with fine emery cloth.
  • Page 72: Cylinder Wear Inspection

    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.
  • Page 73: Piston Ring, Piston Ring Groove Inspection

    ENGINE TOP END 4-9 Cylinder Piston Ring, Piston Ring Groove Inspection • 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.
  • Page 74: Piston, Piston Pin, Connecting Rod Wear Inspection

    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.
  • Page 75: Expansion Chamber Damper Mounting Bolt

    ENGINE TOP END 4-11 Muffler (Expansion Chamber) Muffler Removal • Remove: Right Shroud Right Side Cover • Remove the muffler mounting bolts [B] and pull the muffler [A] off toward the rear. • Remove the springs [A] holding the exhaust pipe holding •...
  • Page 76 4-12 ENGINE TOP END Muffler (Expansion Chamber) • Unscrew the inner pipe mounting bolts [A]. • Pull the inner pipe [B] from the muffler body. • Pull off the old muffler baffle, and install the new muffler baffle [A] into the muffler body. •...
  • Page 77 ENGINE RIGHT SIDE 5-1 Engine Right Side Table of Contents Exploded View........................Specifications ......................... Clutch Cable ........................... Clutch Lever Free Play Inspection ..................Free Play Adjustment......................Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication and Inspection ................Right Engine Cover ........................
  • Page 78: Exploded View

    5-2 ENGINE RIGHT SIDE Exploded View...
  • Page 79 16. Kickstarter Idle Gear 17. Ratchet Gear 18. Kick Gear 19. Kick Shaft 20. KX65-A1 ∼ A6 T1: 8.8 N·m (0.90 kgf·m, 78 in·lb) T2: 64 N·m (6.5 kgf·m, 47 ft·lb) T3: 9.3 N·m (0.95 kgf·m, 82 in·lb) T4: 5.2 N·m (0.53 kgf·m, 46 in·lb) T5: 1.5 N·m (0.15 kgf·m, 13 in·lb)
  • Page 80: Specifications

    5-4 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Clutch 8 ∼ 13 mm Lever Free Play – – – 3.1 ∼ 3.3 mm Friction Plate Thickness 2.9 mm 1.47 ∼ 1.73 mm Steel Plate Thickness 1.37 mm Friction Plate Warp Not more than 0.2 mm 0.3 mm Steel Plate Warp...
  • Page 81: Clutch Cable

    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. WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns.
  • Page 82: Clutch Cable Removal

    5-6 ENGINE RIGHT SIDE Clutch Cable Clutch Cable Removal • Slide the dust cover out of place. • Loosen the adjusting nuts at the lower of the cable, and turn the adjusting nuts to give the cable plenty of play. •...
  • Page 83: Right Engine Cover

    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/Transmission chapter). • Drain the coolant (see Coolant Draining in the Cooling System chapter). • Remove: Water Hose Lower Ends Kick Pedal Clutch Cable Lower End (see this chapter)
  • Page 84 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.
  • Page 85: Right Engine Cover Disassembly

    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]. NOTICE Do not remove the clutch release shaft unless it is absolutely necessary. If removed, you must replace the oil seal with a new ones.
  • Page 86: Clutch Hub Bolt

    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].
  • Page 87: Friction And Steel Plates Wear, Damage Inspection

    ENGINE RIGHT SIDE 5-11 Clutch NOTICE 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.
  • Page 88: Spring Free Length Measurement

    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.
  • Page 89: External Shift Mechanism

    ENGINE RIGHT SIDE 5-13 External Shift Mechanism External Shift Mechanism Removal • Remove: Shift Pedal Right Engine Cover Clutch Housing • Remove the engine mounting bolts [A] to pull out the ex- ternal shift mechanism. • Pull out the external shift mechanism [A], lifting the engine [B].
  • Page 90: Primary Gear

    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 . Special Tools - Outside Circlip Pliers: 57001-144 Primary Gear Installation •...
  • Page 91 ENGINE RIGHT SIDE 5-15 Primary Gear • Install the spring washer [A] with the concave side facing to the inward. • Temporarily tighten the primary gear nut [B]. • Tighten the primary gear nut ○ Primary gear nut is left-hand threads. Torque - Primary Gear Nut: 49 N·m (5.0 kgf·m, 36 ft·lb) Special Tools - Flywheel &...
  • Page 92: Ratchet Guide Bolt

    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].
  • Page 93 ENGINE REMOVAL/INSTALLATION 6-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 94: Exploded View

    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.
  • Page 95: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 6-3 Engine Removal/Installation Engine Removal • Drain the engine oil (see Engine Bottom End/Transmis- sion chapter). • Drain the coolant (see Cooling System chapter). • Remove: Radiator Shrouds Side Covers Seat Fuel Tank Water Hoses Radiators Expansion Chamber Spark Plug Carburetor (with Cables and Hoses) Clutch Cable Lower End...
  • Page 96: Engine Installation

    Torque - Engine Mounting Nuts: 25 N·m (2.5 kgf·m, 18 ft·lb) 29 N·m (3.0 kgf·m, 21 ft·lb): KX65-A3 ∼ Swing Arm Pivot Shaft Nut: 69 N·m (7.0 kgf·m, 51 ft·lb) Shift Pedal Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb) •...
  • Page 97 ENGINE BOTTOM END/TRANSMISSION 7-1 Engine Bottom End/Transmission Table of Contents Exploded View........................Specifications ......................... Transmission Oil ........................Oil Level Inspection......................Oil Change ........................Crankcase ..........................Crankcase Splitting ......................Crankcase Disassembly ....................Crankcase Assembly ......................Crankshaft, Connecting Rod ....................7-10 Crankshaft Removal ......................7-10 Crankshaft Installation ......................
  • Page 98: Exploded View

    7-2 ENGINE BOTTOM END/TRANSMISSION Exploded View...
  • Page 99 11. Operating Plate 12. Shift Drum 13. Shift Shaft 14. Shift Pedal 15. KX65-A1 ∼ A5 16. KX65-A1 ∼ A6 T1: 20 N·m (2.0 kgf·m, 15 ft·lb) T2: 29 N·m (3.0 kgf·m, 21 ft·lb) T3: 8.8 N·m (0.90 kgf·m, 78 in·lb) T4: 8.8 N·m (0.90 kgf·m, 78 in·lb)
  • Page 100: Specifications

    7-4 ENGINE BOTTOM END/TRANSMISSION Specifications Item Standard Service Limit Transmission Oil: Engine Oil: API SG, SH, SJ, SL or SM with JASO MA, Grade – – – MA1 or MA2 Viscosity SAE10W-40 – – – Capacity 0.5 L – – – Crankshaft, Connecting Rod Connecting Rod Bend Not more than 0.05 mm/100 mm...
  • Page 101: Transmission Oil

    ENGINE BOTTOM END/TRANSMISSION 7-5 Transmission Oil In order for the transmission and clutch to function prop- erly, always maintain the transmission oil at the proper level and change the oil periodically. WARNING Vehicle operation with insufficient, deteriorated, or contaminated transmission oil will cause acceler- ated wear and may result in engine or transmission seizure, accident, and injury.
  • Page 102 7-6 ENGINE BOTTOM END/TRANSMISSION Transmission 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.
  • Page 103: Crankcase

    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. • Remove: Magneto Cover Output Shaft Sleeve [A] and O-ring [B] Cylinder Head (see Engine Top End Chapter) Cylinder (see Engine Top End Chapter) Piston (see Engine Top End Chapter)
  • Page 104: Crankcase Disassembly

    7-8 ENGINE BOTTOM END/TRANSMISSION Crankcase • Pull out the shift rods [A]. • Disengage the shift fork guide pins from the shift drum grooves. • Take off the shift drum [B] • Remove the shift forks [C] from the transmission gears. •...
  • Page 105 ENGINE BOTTOM END/TRANSMISSION 7-9 Crankcase • Turn 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.
  • Page 106: Crankshaft, Connecting Rod

    7-10 ENGINE BOTTOM END/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the transmission shafts (see Transmission Shaft Removal). • Using a press, remove the crankshaft from the right crankcase. ○ If the bearings stay on the crankshaft when splitting the crankcase or removing the crankshaft from the right crankcase, remove the bearings from the crankshaft with a bearing puller [A] and adapter [B].
  • Page 107: Connecting Rod Big End Radial Clearance Inspection

    ENGINE BOTTOM END/TRANSMISSION 7-11 Crankshaft, Connecting Rod Connecting Rod Big End Radial Clearance Inspection • Set the crankshaft in a flywheel alignment 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.
  • Page 108: Crankshaft Alignment Inspection

    7-12 ENGINE BOTTOM 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.
  • Page 109: Transmission

    ENGINE BOTTOM END/TRANSMISSION 7-13 Transmission 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.
  • Page 110: Shift Drum And Fork Installation

    7-14 ENGINE BOTTOM END/TRANSMISSION Transmission • 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.
  • Page 111: Shift Fork Bending Inspection

    ENGINE BOTTOM END/TRANSMISSION 7-15 Transmission • 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. •...
  • Page 112: Gear Damage Inspection

    7-16 ENGINE BOTTOM END/TRANSMISSION Transmission Gear Damage Inspection • Visually inspect the gear teeth on the transmission gears. Repair lightly damaged gear teeth with an oilstone. The gear must be replaced if the teeth are badly damaged. When gear is repaired or replaced, the driving gear should also be inspected and repaired or replaced if necessary.
  • Page 113 WHEELS/TIRES 8-1 Wheels/Tires Table of Contents Exploded View........................Specifications ......................... Wheels (Rims) ........................Front Wheel Removal ....................... Front Wheel Installation ....................Rear Wheel Removal......................Rear Wheel Installation..................... Wheels Inspection......................Spoke Inspection ......................Rim Inspection ........................Axle Inspection........................Tires............................Air Pressure Inspection/Adjustment.................. Tires Inspection.........................
  • Page 114: Exploded View

    8-2 WHEELS/TIRES Exploded View 1. Nipple 2. Spoke 3. Front Tire 4. Rim 5. Front Axle 6. Swingarm 7. Rear Tire 8. Rear Axle T1: 1.5 N·m (0.15 kgf·m, 13 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.
  • Page 115: Specifications

    98 kPa (1.0 kgf/cm², 14 psi) – – – Tires Standard Tire: Front: Size 60/100-14 30M – – – Make DUNLOP D755F, Tube (KX65-A1 ∼ A6) Type D756F, Tube Rear: Size 80/100-12 41M – – – Make DUNLOP D755, Tube (KX65-A1 ∼ A6)
  • Page 116: Front Wheel Removal

    8-4 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Using the jack [A] under the frame, and stabilize the mo- torcycle. Special Tool - Jack: 57001-1238 • Place a stand under the engine to raise the front wheel the ground. • Remove the cotter pin [A] •...
  • Page 117: Rear Wheel Removal

    WHEELS/TIRES 8-5 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if 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. ○...
  • Page 118: Rear Wheel Installation

    8-6 WHEELS/TIRES Wheels (Rims) • Remove the cotter pin [A]. • Remove the axle nut [B]. • Pull out the axle [C]. • Move the rear wheel back with the rear caliper installed. • Take off the collar and cap from the each side of the rear hub.
  • Page 119: Wheels Inspection

    WHEELS/TIRES 8-7 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if 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. ○...
  • Page 120: Rim Inspection

    8-8 WHEELS/TIRES Wheels (Rims) Rim Inspection • Remove the wheel, and support it with the tire by the axle. • 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.
  • Page 121: Tires

    Check and balance the wheel when a tire is replaced with a new one. Standard Tire Front: Size: 60/100-14 30M Make: DUNLOP D755F, Tube (KX65-A1 ∼ A6) Type: D756F, Tube Rear: Size: 80/100-12 41M Make: DUNLOP D755, Tube (KX65-A1 ∼ A6)
  • Page 122: Tire Removal

    8-10 WHEELS/TIRES Tires Tire Removal NOTICE 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).
  • Page 123: Tire Installation

    WHEELS/TIRES 8-11 Tires Tire Installation • 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. • Position the tire on the rim so that the valve [A] is at the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire.
  • Page 124: Hub Bearings

    8-12 WHEELS/TIRES Hub Bearings Hub Bearing Removal • Remove the wheel (see Wheel Removal). NOTICE 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.
  • Page 125: Bearing Inspection

    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. • Apply high temperature grease to the oil seal lips. Special Tool - Bearing Driver set: 57001-1129 [C] Inside Circlip Pliers: 57001-143 Bearing Inspection...
  • Page 127 FINAL DRIVE 9-1 Final Drive Table of Contents Exploded View........................Specifications ......................... Drive Chain..........................Drive Chain Slack Inspection .................... Drive Chain Slack Adjustment ..................Wheel Alignment Inspection ..................... Wheel Alignment Adjustment.................... Drive Chain Wear Inspection .................... Drive Chain Lubrication..................... Drive Chain Removal ......................Drive Chain Installation .....................
  • Page 128: Exploded View

    Exploded View 1. Engine Sprocket 10. Rear Sprocket 2. Output Shaft 11. Rear Axle 12. KX65-A6, A6F ∼ 3. Swingarm 4. Chain Slipper T1: 26 N·m (2.7 kgf·m, 20 ft·lb) 5. Chain Guide T2: 79 N·m (8.0 kgf·m, 58 ft·lb) 6.
  • Page 129: Specifications

    Specifications Item Standard Service Limit Drive Chain 44 ∼ 54 mm Chain Slack – – – 45 ∼ 55 mm (KX65-A3 ∼) – – – 254.0 ∼ 254.6 mm 259 mm Chain 20-link Length Standard Chain: Make DAIDO – – –...
  • Page 130: Drive Chain

    If the drive chain slack exceeds the standard, adjust it. Chain Slack Standard: KX65-A1 ∼ 44 ∼ 54 mm KX65-A3 ∼ 45 ∼ 55 mm Drive Chain Slack Adjustment •...
  • Page 131: Wheel Alignment Inspection

    In wet and muddy conditions, mud sticks to the chain and sprockets resulting in an overly tight chain, and the chain may break. To prevent this, adjust the chain to 54 ∼ ∼ ∼ 64 mm (KX65-A3 , 55 65 mm) of slack whenever necessary. Wheel Alignment Inspection •...
  • Page 132: Drive Chain Lubrication

    Make: DAIDO Type: DID 420MBK1 Link: 108 Links 110 Links (KX65-A3 ∼) Drive Chain Lubrication • If the chain appears especially dirty, it should be cleaned before lubrication with high flash-point solvent. • If a special lubricant is not available, a heavy oil such as SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication.
  • Page 133: Drive Chain Installation

    FINAL DRIVE 9-7 Drive Chain Drive Chain Installation • 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].
  • Page 134: Sprockets

    9-8 FINAL DRIVE Sprockets Engine Sprocket Removal • Remove: Magneto Cover Drive Chain [A] (free of engine sprocket) • Remove the circlip [B], and pull off the engine sprocket [C]. Special Tool - Outside Circlip Pliers: 57001-144 Engine Sprocket Installation •...
  • Page 135: Rear Sprocket Warp Inspection

    FINAL DRIVE 9-9 Sprockets Rear Sprocket Warp Inspection • Using the jack, raise the rear wheel off the ground. Special Tool - 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).
  • Page 137 BRAKES 10-1 Brakes Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Brake Lever, Brake Pedal....................... 10-5 Brake Lever Play Adjustment.................... 10-5 Brake Pedal Position/Pedal Play Adjustment ..............10-5 Brake Pedal Removal ....................... 10-5 Brake Pedal Installation ....................10-6 Brake Fluid ..........................10-7 Fluid Level Inspection .......................
  • Page 138: Exploded View

    10-2 BRAKES Exploded View 1. Front Brake Reservoir T1: 25 N·m (2.5 kgf·m, 18 ft·lb) 2. Brake Lever T2: 8.8 N·m (0.90 kgf·m, 78 in·lb) 3. Brake Hose T3: 7.8 N·m (0.80 kgf·m, 69 in·lb) 4. Clamps T4: 18 N·m (1.8 kgf·m, 13 ft·lb) 5.
  • Page 139 BRAKES 10-3 Exploded View 1. Rear Brake Reservoir T1: 25 N·m (2.5 kgf·m, 18 ft·lb) 2. Rear Master Cylinder T2: 9.8 N·m (1.0 kgf·m, 87 in·lb) 3. Brake Hose T3: 7.8 N·m (0.80 kgf·m, 69 in·lb) 4. Brake Pedal T4: 18 N·m (1.8 kgf·m, 13 ft·lb) 5.
  • Page 140: Specifications

    10-4 BRAKES Specifications Item Standard Service Limit Brake Adjustment Lever Play Adjustable (to suit rider) – – – Brake Fluid Recommended Disc Brake Fluid: – – – Type DOT3 or DOT4 – – – Brake Pads Lining Thickness: Front 4.5 mm 0.7 mm Rear 4.5 mm...
  • Page 141: Brake Lever, Brake Pedal

    BRAKES 10-5 Brake Lever, Brake Pedal Brake Lever Play 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.
  • Page 142: Brake Pedal Installation

    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. If necessary, replace them with new one. •...
  • Page 143: Brake Fluid

    BRAKES 10-7 Brake Fluid WARNING 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.
  • Page 144: Fluid Level Inspection

    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 ○...
  • Page 145 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 brake. • Level the brake fluid reservoir. • Remove the reservoir cap. •...
  • Page 146: Bleeding The Brake Line

    10-10 BRAKES Brake Fluid Bleeding the Brake Line The brake fluid has a very low compression coefficient 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. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air.
  • Page 147 BRAKES 10-11 Brake Fluid • Remove the clear plastic hose. • Tighten the bleed valves, and install the rubber cap. Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb) • Check the fluid level. • After bleeding is done, check the brake for good braking power, no brake drag, and no fluid leakage.
  • Page 148: Caliper

    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]. • Remove the banjo bolt and take off the brake hose from the caliper [C]. •...
  • Page 149: Caliper Disassembly

    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). ○...
  • Page 150: Fluid Seal Damage Inspection

    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).
  • Page 151: Brake Pad Removal

    BRAKES 10-15 Caliper Brake Pad Removal • Loosen the pad bolts [A]. • Remove the caliper [B]. • Remove the pad bolts. • Take out the piston side pad. • Push the caliper holder toward the piston, and then re- move another pad from the caliper holder.
  • Page 152: Master Cylinder

    10-16 BRAKES Master Cylinder NOTICE Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately. Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the upper brake hose from the master cylinder (see Brake Hose Re- moval/Installation).
  • Page 153: Rear Master Cylinder Removal

    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.
  • Page 154: Rear Master Cylinder Disassembly

    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 Tool - Inside Circlip Pliers: 57001-143 •...
  • Page 155: Master Cylinder Inspection (visual Inspection)

    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].
  • Page 156: Brake Disk

    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. Thickness Standard: 2.80 ∼...
  • Page 157: Brake Hose

    BRAKES 10-21 Brake Hose Brake Hose Removal/Installation NOTICE 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.
  • Page 159 Table of Contents Exploded View........................11-2 Specifications ......................... 11-6 Front Fork ..........................11-7 Rebound Damping Adjustment (KX65-A3 ∼) ..............11-7 Fork Oil Level Adjustment (Simplify)................. 11-7 Oil Change/Oil Level Adjustment (each fork leg) .............. 11-9 Front Fork Removal ......................11-10 Front Fork Installation .......................
  • Page 160: Exploded View

    11-2 SUSPENSION Exploded View...
  • Page 161 13. Allen Bolt 14. Steering Stem Head 15. Steering Stem 16. Spring Seat 17. KX65-A3 ∼ T1: 22 N·m (2.2 kgf·m, 16 ft·lb) T2: 20 N·m (2.0 kgf·m, 14 ft·lb) T3: 29 N·m (3.0 kgf·m, 22 ft·lb) T4: 44 N·m (4.5 kgf·m, 33 ft·lb)
  • Page 162 11-4 SUSPENSION Exploded View...
  • Page 163 2. Swingarm 3. Rocker Arm 4. Tie-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 (3.5 kgf·m, 25 ft·lb) T5: 39 N·m (4.0 kgf·m, 29 ft·lb)
  • Page 164: Specifications

    88.8 mm (KX65-A1) ∼ A2) (Adjusting nut position from the 86.6 mm (KX65-A2) center of the upper mounting hole) 79.6 mm (KX65-A3 ∼ A6) 75.6 ∼ 83.6 mm (KX65-A3 ∼ A6) 80.1 mm (KX65A6F ∼) 76.1 ∼ 84.1 mm (KX65A6F ∼) Rear Shock Spring Free Length 206.1 mm...
  • Page 165: Front Fork

    Also, it tends to understeer in turns and “wash out”. When the height is greater, the results are opposite. ∼ Rebound Damping Adjustment (KX65-A3 • To adjust rebound damping, turn the adjuster [A] on the front fork top plugs with the blade of a screwdriver until you feel a click.
  • Page 166 98 ∼ 140 mm (KX65-A1) Adjustable Range: 96 ∼ 139 mm (KX65-A2) 98 ∼ 142 mm (KX65-A3 ∼) If no oil is drawn out, there is insufficient oil in the fork tube. Pour in enough oil, then pump out the excess oil.
  • Page 167: Oil Change/oil Level Adjustment (each Fork Leg)

    • Install the fork top plug. • Install the fork top plug and fork spring seat (KX65-A3 ∼). • Tighten the fork top plug. Torque - Front Fork Top Plug: 22 N·m (2.2 kgf·m, 16 ft·lb) •...
  • Page 168: Front Fork Removal

    98 ∼ 140 mm (KX65-A1) Adjustable Range: 96 ∼ 139 mm (KX65-A2) 98 ∼ 142 mm (KX65-A3 ∼) If no oil is drawn out, there is insufficient oil in the fork tube. Pour in enough oil, then drawn out the excess oil.
  • Page 169: Front Fork Installation

    Install the fork so that the top end [A] of the inner tube is 20 mm up [B] with the upper surface [C] of the steering stem head (KX65-A3 ∼). • Route the cables and hose according to the Cable, Wire and Hose Routing section in the General Information chapter.
  • Page 170 11-12 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. Special Tool - Fork Outer Tube Weight: 57001-1218 ○...
  • Page 171: Front Fork Assembly (each Fork)

    Torque - Fork Bottom Allen Bolts: 20 N·m (2.0 kgf·m, 14 ft·lb) Special Tools - Fork Cylinder Holder Handle: 57001-183 (use for KX65-A1 ∼ A2) Fork Cylinder Holder Adapter: 57001-1011 (use for KX65-A1 ∼ A2) • Install the guide bush [A] (with a used guide bush [B] on it) by tapping [C] the used guide bush with the fork oil seal driver [D] until it stops.
  • Page 172: Inner Tube Inspection

    Fork Spring Free Length Standard: 455.7 mm (KX65-A1) 470.7 mm (KX65-A2) 497.1 mm (KX65-A3 ∼) Service Limit: 446.6 mm (KX65-A1) 461.3 mm (KX65-A2) 487.2 mm (KX65-A3 ∼)
  • Page 173: Rear Suspension (uni-trak)

    To 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. KX65-A3 ∼ The damping force can be adjusted easily so changing oil viscosity unnecessary.
  • Page 174: Rear Shock Absorber Removal

    Standard: 88.8 mm (KX65-A1) 86.6 mm (KX65-A2) 79.6 mm (KX65-A3 ∼ A6) 80.1 mm (KX65A6F ∼) 82.8 ∼ 94.8 mm (KX65-A1 ∼ A2) Adjustable Range: 75.6 ∼ 83.6 mm (KX65-A3 ∼ A6) 76.1 ∼ 84.1 mm (KX65A6F ∼) • Tighten the locknut securely.
  • Page 175: Rear Shock Absorber Installation

    SUSPENSION 11-17 Rear Suspension (Uni-Trak) • 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. • Tighten the following: Torque - Rear Shock Absorber Mounting Bolt (Upper): 39 N·m (4.0 kgf·m, 29 ft·lb) Rear Shock Absorber Mounting Nut (Lower): 34...
  • Page 176: Spring Tension

    Rear Shock Absorber Spring Free Length 206.1 mm (KX65-A1 ∼ A2) Standard: 211.1 mm (KX65-A3 ∼) Service Limit: 202.0 mm (KX65-A1 ∼ A2) 206.9 mm (KX65-A3 ∼) Rear Shock Absorber Scrapping WARNING Since the reservoir tank of the rear shock absorber...
  • Page 177: Swingarm

    SUSPENSION 11-19 Swingarm Swingarm Removal • Place the jack under the frame so that the rear wheel is off the ground. Special Tool - Jack: 57001-1238 • Remove the rear wheel (see Wheels/Tires chapter). • Remove the brake pedal [A]. •...
  • Page 178: Swingarm Bearing Installation

    11-20 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.
  • Page 179: Tie-rod, Rocker Arm

    SUSPENSION 11-21 Tie-rod, Rocker Arm Tie-rod Removal • Using the jack under the frame, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 • Remove the tie-rod front mounting bolt [A]. NOTICE When pulling out the mounting bolts, lift the rear wheel slightly.
  • Page 180: Rocker Arm Installation

    11-22 SUSPENSION Tie-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.
  • Page 181: Uni-trak Maintenance

    SUSPENSION 11-23 Uni-Trak 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 Tool - Jack: 57001-1238 • Push and pull on the swingarm [A], up and down, to check for wear.
  • Page 183 STEERING 12-1 Steering Table of Contents Exploded View........................12-2 Specifications ......................... 12-3 Steering ..........................12-4 Steering Inspection ......................12-4 Steering Adjustment......................12-4 Steering Stem, Stem Bearing Removal ................12-5 Steering Stem, Stem Bearing Installation ................. 12-6 Steering Maintenance......................12-8 Stem Bearing Lubrication....................12-8 Stem Bearing Wear, Damage Inspection................
  • Page 184: Exploded View

    12-2 STEERING Exploded View 1. Handlebar Clamp T1: 44 N·m (4.5 kgf·m, 33 ft·lb) 2. Handlebar T2: 20 N·m (2.0 kgf·m, 15 ft·lb) 3. Steering Stem Head Nut T3: 2.9 N·m (0.30 kgf·m, 26 in·lb) 4. Steering Stem Head Bracket T4: 25 N·m (2.5 kgf·m, 18 ft·lb) 5.
  • Page 185: Specifications

    STEERING 12-3 Specifications Special Tools - Steering Stem Bearing Driver: 57001-137 Head Pipe Outer Race Press Shaft: 57001-1075 Steering Stem Bearing Driver Adapter: 57001-1092 Steering Stem Nut Wrench: 57001-1100 Head Pipe Outer Race Driver: 57001-1106 Head Pipe Outer Race Remover: 57001-1107 Jack: 57001-1238...
  • Page 186: Steering Inspection

    12-4 STEERING Steering Steering Inspection • Using the jack, raise the front wheel off the ground. Special Tool - 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.
  • Page 187: Steering Stem, Stem Bearing Removal

    STEERING 12-5 Steering Steering Stem, Stem Bearing Removal • Remove: Front Wheel (see Wheels/Tires chapter) Brake Hose Clamp (see Brake System chapter) Caliper Mounting Bolts (see Brake System chapter) Master Cylinder Clamp (see Brake System chapter) Front Fender Handlebar (see Handlebar Removal) Front Fork (see Suspension chapter) •...
  • Page 188: Steering Stem, Stem Bearing Installation

    12-6 STEERING 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]. Special Tools - Head Pipe Outer Race Press Shaft: 57001 -1075 Head Pipe Outer Race Driver: 57001-1106...
  • Page 189 STEERING 12-7 Steering Torque - 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, 15 ft·lb) Lower: 29 N·m (3.0 kgf·m, 22 ft·lb) • Install the parts removed (see the appropriate chapter). WARNING Do not impede the handlebar turning by routing the cables, wires and hoses improperly (see the Gen-...
  • Page 190: Steering Maintenance

    12-8 STEERING 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.
  • Page 191: Handlebar

    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].
  • Page 193 ELECTRICAL SYSTEM 13-1 Electrical System Table of Contents Wiring Diagram........................13-2 Exploded View........................13-3 Specifications ......................... 13-4 Precautions..........................13-5 Electrical Wiring........................13-6 Wiring Inspection ......................13-6 Ignition Timing ........................13-7 Ignition Timing Adjustment....................13-7 Flywheel Magneto ........................13-8 Flywheel Magneto Removal....................13-8 Flywheel Magneto Installation...................
  • Page 194: Wiring Diagram

    13-2 ELECTRICAL SYSTEM Wiring Diagram KX65A6F ∼...
  • Page 195: Exploded View

    5. Ignition Coil 6. Spark Plug Cap 7. Spark Plug 8. Engine Stop Button 9. KX65-A1 ∼ A6 T1: 29 N·m (3.0 kgf·m, 21 ft·lb) T2: 4.9 N·m (0.50 kgf·m, 43 in·lb) T3: 25 N·m (2.6 kgf·m, 19 ft·lb) T4: 8.8 N·m (0.90 kgf·m, 78 in·lb)
  • Page 196: Specifications

    0.31 Ω ±15% (at 20°C) Secondary Winding Resistance 3.1 kΩ ±15% (at 20°C) Spark Plug: Type NGK BR10EG NGK B10EG (KX65-A1 ∼ A6 (US)) 0.5 ∼ 0.6 mm CDI. unit: in the text Special Tools - Flywheel Puller: 57001-252 Flywheel & Pulley Holder: 57001-1343...
  • Page 197: Precautions

    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. Such a shock to the parts can damage them.
  • Page 198: Electrical Wiring

    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. If the connector is corroded or dirty, clean it carefully.
  • Page 199: Ignition Timing

    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 stator [D].
  • Page 200: Flywheel Magneto

    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]. Special Tool - Flywheel & Pulley Holder: 57001-1343 • Screw the flywheel puller [A] into the flywheel by turning it counterclockwise (left-hand thread).
  • Page 201: Crankshaft Sensor Air Gap Inspection (kx65a6f ~)

    ELECTRICAL SYSTEM 13-9 Flywheel Magneto • Using a high flash-point solvent, clean off any oil or dirt that may be on the crankshaft taper [A] or in the hole [B] in the flywheel. Dry them with a clean cloth. • Fit the woodruff key [A] securely in the slot in the crank- shaft before installing the stator plate.
  • Page 202 13-10 ELECTRICAL SYSTEM Flywheel Magneto • To check the stator coil resistance as follows. ○ Connect the hand tester to the terminals of the harness connector [A] as shown in the table 2. ○ Note the readings. Table 2 Stator Coil Resistance Connections Tester Range Reading...
  • Page 203: Ignition System

    ELECTRICAL SYSTEM 13-11 Ignition System Safety Instructions WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. ∼...
  • Page 204: Crankshaft Sensor Peak Voltage Inspection (kx65a6f ~)

    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 voltage adapter [A] as shown in the diagram.
  • Page 205 ELECTRICAL SYSTEM 13-13 Ignition System WARNING To 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. 3 Needle Arcing Distance Standard: 7 mm or more •...
  • Page 206: Spark Plug Cleaning And Inspection

    [B] with a suitable tool to obtain the correct gap. Spark Plug Gap 0.5 ∼ 0.6 mm Standard: CDI Unit Removal • Turn the handlebar to the right. (KX65-A1 ∼ A6) • Disconnect the harness connector [A]. • Unscrew the mounting bolt [B] and remove the CDI Unit [C].
  • Page 207 ELECTRICAL SYSTEM 13-15 Ignition System Ignition Coil Primary Peak Voltage Check • Remove: Shrouds Side Covers Seat Fuel Tank • 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.
  • Page 208 13-16 ELECTRICAL SYSTEM Ignition System...
  • Page 209 ELECTRICAL SYSTEM 13-17 Ignition System Exciter (Stator) Coil Peak Voltage Check • Disconnect the connector of the harness from the CDI Unit. • To check the peak voltage, do the following procedures. NOTE ○ Measure the voltage with each lead connected cor- rectly.
  • Page 211 APPENDIX 14-1 Appendix Table of Contents Troubleshooting Guide ......................14-2 General Lubrication ........................ 14-6 Lubrication (Periodic Maintenance) .................. 14-6 Nut, Bolt, and Fastener Tightness ..................14-7 Tightness Inspection ......................14-7 Unit Conversion Table ......................14-8...
  • Page 212: Troubleshooting Guide

    14-2 APPENDIX Troubleshooting Guide NOTE Cylinder head warped ○ This is not an exhaustive list, giving every Cylinder base gasket damaged possible cause for each problem listed. It Read valve damaged is meant simply as a rough guide to assist Cylinder nut loose the troubleshooting for some of the more Poor Running at Low Speed:...
  • Page 213 APPENDIX 14-3 Troubleshooting Guide Flywheel magneto damaged CDI Unit trouble Ignition coil lead or CDI Unit lead not in good Fuel/air mixture incorrect: contact Main jet clogged or wrong size Fuel/air mixture incorrect: Fuel level in carburetor float bowl too low Main jet clogged or wrong size Carburetor holder loose Jet needle or needle jet worn...
  • Page 214: Abnormal Frame Noise

    14-4 APPENDIX Troubleshooting Guide Jumps out of gear: Output shaft idle gear worn or chipped Shift fork worn Drive chain noise: Gear groove worn Drive chain adjusted improperly Gear dogs and/or dog holes worn Chain worn Shift drum groove worn Rear and/or engine sprocket(s) worn Gear positioning lever spring weak or bro- Chain lubrication insufficient...
  • Page 215 APPENDIX 14-5 Troubleshooting Guide Wheel misalignment Front fork, rear shock absorber spring weak Swingarm bent or twisted Rear shock absorber gas leaking Swingarm pivot shaft runout excessive Rear shock absorber maladjusted Steering maladjusted Brake Doesn’t Hold: Steering stem bent Front fork leg bent Disc brake: Right/left front fork oil level uneven Air in the brake line...
  • Page 216: General Lubrication

    14-6 APPENDIX General Lubrication Lubrication (Periodic Maintenance) • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubri-...
  • Page 217: Nut, Bolt, And Fastener Tightness

    APPENDIX 14-7 Nut, Bolt, and Fastener Tightness 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).
  • Page 218: Unit Conversion Table

    14-8 APPENDIX Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 milli × 0.001 Units of Torque: micro µ...
  • Page 219 MODEL APPLICATION Year Model Beginning Frame No. □ JKBKEAC YA000001 or 2000 KX65-A1 JKAKX065AAA000001 □ JKBKXEAC 1A009001 or 2001 KX65-A2 JKBKX065AAA009001 □ JKBKXEAC 2A016001 or 2002 KX65-A3 JKBKX065AAA016001 □ JKBKXEAC 3A027001 or 2003 KX65-A4 JKBKX065AAA027001 □ JKBKXEAC 4A036001 or 2004...

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