Kawasaki KX65 - Manual

This motorcycle is designed for a rider weighing less than 121 pounds (55 kg). Exceeding thislimit 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 andrepair work. A basic knowledge of mechanics,the proper use...

GENERAL INFORMATION 1-1 1 General Information Table of Contents Before Servicing ..................................................................................................................... 1-2 Model Identification................................................................................

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 ...

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...

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 Dent Scratch Wear Co...

GENERAL INFORMATION 1-5 Model Identification KX65-A1 Left Side View KX65-A1 Right Side View

1-6 GENERAL INFORMATION 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 Height 925 mm (KX65-A1), 935 mm (KX65-A2) 955 mm Wheelbase 1 110 mm 1 120 mm Road Clearance 270 mm (KX65-A...

GENERAL INFORMATION 1-7 General Specifications Items KX65-A1 ∼ A2 KX65-A3 ∼ A6, A6F ∼ 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 ← Gear Ratios: 1st 2.846 (37/13) ← 2nd 2.125 (...

1-8 GENERAL INFORMATION General Specifications Items KX65-A1 ∼ A2 KX65-A3 ∼ A6, A6F ∼ Brake Type: 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. US: United States Model

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 OPERATION After each race (or 2.5 hr.) Every 3 races (or 7.5 hr.) Every 5 races (or 12.5 hr.) Every 10 races (or 25 hr.) As requir...

1-10 GENERAL INFORMATION Periodic Maintenance Chart FREQUENCY OPERATION After each race (or 2.5 hr.) Every 3 races (or 7.5 hr.) Every 5 races (or 12.5 hr.) Every 10 races (or 25 hr.) As required Fuel hoses, connections - inspect † • Steering play - inspect † • Steering stem bearing - grease • Rear s...

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. Thefollowing table lists the tightening torque for t...

1-12 GENERAL INFORMATION Torque and Locking Agent Torque 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/Transmission Cylinder Stud – – – L (Planted Side) Cra...

GENERAL INFORMATION 1-13 Torque and Locking Agent Torque 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 2.9 0.30 26 in·lb Handlebar Clamp Bolts 25 2.5 18 ...

1-14 GENERAL INFORMATION Special Tools and Sealants Bearing Puller Adapter:57001-136 Steering Stem Bearing Driver:57001-137 Inside Circlip Pliers:57001-143 Outside Circlip Pliers:57001-144 Bearing Puller:57001-158 Fork Cylinder Holder Handle:57001-183 Flywheel Puller, M12 × 1.75:57001-252 Piston Pin...

GENERAL INFORMATION 1-15 Special Tools and Sealants Rim Protector:57001-1063 Bead Breaker Assembly:57001-1072 Head Pipe Outer Race Press Shaft:57001-1075 Steering Stem Bearing Driver Adapter, 29.7:57001-1092 Steering Stem Nut Wrench:57001-1100 Hook Wrench R37.5, R42:57001-1101 Head Pipe Outer Race D...

1-16 GENERAL INFORMATION Special Tools and Sealants Front Fork Oil Seal Driver:57001-1219 Jack:57001-1238 Fork Oil Level Gauge:57001-1290 Crankcase Splitting Tool Assembly:57001-1362 Hand Tester:57001-1394 Peak Voltage Adapter:57001-1415 Crank Shaft Jig:57001-1439 Graduated Cylinder & Tube:57001...

GENERAL INFORMATION 1-17 Special Tools and Sealants Kawasaki Bond (Silicone Sealant):56019-120 Kawasaki Bond (Liquid Gasket - Silver):92104-002

1-18 GENERAL INFORMATION Cable, Wire and Hose Routing 1. Throttle Cable2. Carburetor3. Breather Hose4. Air Vent Hose5. Overflow Hose6. The hoses are passed from the left side of the engine through the clamp in order ofthe air vent hose, the overflow hose andthe breather hose as shown in figure. 7. C...

GENERAL INFORMATION 1-19 Cable, Wire and Hose Routing 1. Breather Hose2. Run the throttle cable under the breather hose.3. Radiator4. CDI Unit (KX65-A1 ∼ A6) 5. Clamp (KX65-A1 ∼ A6) 6. Throttle Cable7. Clamp as shown in figure. (Be sure the clamp screw position is inside.)8. Clamp as shown in figure...

1-20 GENERAL INFORMATION Cable, Wire and Hose Routing 1. Clamp2. CDI Unit (KX65-A1 ∼ A6) 3. Band4. Clamp the magneto leads at the upper part of the left on the carburetor holder.5. Magneto Leads6. Shift Pedal7. 19 ±10 mm (Shift Pedal Position)8. Engine Stop Button Lead9. Ignition Coil 10. Engine Sto...

GENERAL INFORMATION 1-21 Cable, Wire and Hose Routing 1. Front Brake Reservoir2. Banjo Bolts3. Clamp4. Front Brake Disk5. Bleed Valves6. Front Brake Caliper7. Rear Brake Caliper8. Rear Brake Disk9. Rear Brake Reservoir 10. Rear Brake Master Cylinder 11. Bend the cotter pin end by along the joint pin...

1-22 GENERAL INFORMATION Cable, Wire and Hose Routing KX65A6F ∼ 1. Throttle Cable2. Clutch Cable3. Band4. Engine Stop Button Lead5. Clamp6. CDI unit7. Band8. CDI unit Ground Lead9. Ignition Coil Primary Lead 10. Ignition Coil Ground Lead 11. Ignition Coil 12. Band13. Clamp the Magneto Lead

FUEL SYSTEM 2-1 2 Fuel System Table of Contents Exploded View ........................................................................................................................ 2-2 Specifications .....................................................................................................

2-2 FUEL SYSTEM Exploded View 1. Throttle Cable2. Throttle Grip3. Carburetor Holder4. Carburetor Cap5. Spring6. Retainer7. Jet Needle Clip8. Jet Needle9. Throttle Valve 10. Choke Knob 11. Idle Adjusting Screw 12. Spring 13. Air Screw14. Slow Jet15. Float Valve Needle16. Main Jet17. Float18. Reed Val...

2-4 FUEL SYSTEM Specifications Standard Item KX65-A1 ∼ A2 KX65-A3 ∼ Service Limit Throttle Grip Free Play and Cable 2 ∼ 3 mm ← – – – Carburetor Make/Type MIKUNI VM24SS ← – – – Main Jet #230 #190 – – – Throttle Valve Cutaway #2 #1.5 – – – Jet Needle 5HS59 5G SP68 – – – Jet Needle Clip Position 3rd gr...

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 throttleresponse. Also, the throttle valve may not open fully at fullthrottle. On the other hand, if the throttle grip has no play,the throttle will b...

2-6 FUEL SYSTEM Throttle Grip and Cable Cable Lubrication Whenever the cable is removed, and in accordance with the Periodic Maintenance Chart (see General Informationchapter), do the following. • Apply a thin coating of grease [A] to the cable upper end. • Lubricate the cable [A] with a penetrating...

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 leana mixture (too little fuel). Such trouble can be caused bydirt, wear, maladjustment, or improp...

2-8 FUEL SYSTEM Carburetor • Remove the carburetor, and hold it in true vertical positionon a stand. The fuel hose and carburetor cable do nothave to be removed to inspect the fuel level [A]. • Put the fuel tank on a bench, and connect the fuel tap tothe carburetor using a suitable hose. • Remove th...

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 changethe float height. Increasing the float height lowers the fuellevel and decreasing the float height raises the fuel level. Float Height Standard: 21.1 ±1 mm N...

2-10 FUEL SYSTEM Carburetor • Unscrew the carburetor cap [A], and pull out the throttlevalve assembly [B]. CAUTION If the throttle valve is left attached to the cable, wrapit in a clean cloth to avoid damage. • After removing the carburetor, push a clean, lint-free towelinto the carburetor holder an...

FUEL SYSTEM 2-11 Carburetor • Turn the fuel tap to the ON position, and check for fuelleakage 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 ...

2-12 FUEL SYSTEM Carburetor ○ Slide the jet needle out of the throttle valve. ○ Pull out the snap ring [A], and remove the throttle cablefrom the carburetor cap [B]. • Disassemble the carburetor body. Choke Plunger Assembly [A] (unscrew)Idle Adjusting Screw, Spring and O-ring [B] (unscrew)Air Screw ...

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 thecarburetor as possible before cleaning the carbu-retor with a cleaning solution. This will preventdamage or deterioratio...

2-14 FUEL SYSTEM Carburetor • Check the tapered portion [A] of the pilot screw [B] forwear 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]. • Check the plastic tip [A] for wear...

FUEL SYSTEM 2-15 Air Cleaner Air Cleaner Housing Removal • Remove: Radiator ShroudsSide CoversSeatRear FenderRear FlapRear Frame Mounting Bolts [A]Rear Frame [B]Air Cleaner Housing Mounting Bolts [C] • Loosen the air cleaner duct clamp [D]. • Remove the air cleaner housing [E]. Air Cleaner Housing I...

2-16 FUEL SYSTEM Air Cleaner • Install the element [A]. ○ The element tab [B] position is put on whichever of theholder. Element Cleaning and Inspection NOTE ○ In dusty areas, the element should be cleaned morefrequently than recommended interval. ○ After riding through rain or on muddy roads, the e...

FUEL SYSTEM 2-17 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex-plosive under certain conditions. Always stop theengine and do not smoke. Make sure the area iswell-ventilated and free from any source of flameor sparks; this includes any appliance with a pilotlight....

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, itmay allow dirt to reach the carburetor, causing poor run-ning. Replace the fuel tap.If the fuel t...

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], ali...

2-20 FUEL SYSTEM Fuel Hose Fuel Hoses and Connections Check ○ Check the fuel hose periodically in accordance with thePeriodic Maintenance Chart, and if the motorcycle is notproperly handled, the inside the fuel line can cause fuelto leak [A] or the hose to burst. Remove the fuel tank andcheck the fu...

COOLING SYSTEM 3-1 3 Cooling System Table of Contents Exploded View ........................................................................................................................ 3-2 Specifications ...............................................................................................

3-2 COOLING SYSTEM Exploded View 1. Radiator2. Radiator Cap3. Water Pump Cover4. Drain Plug5. Impeller6. Oil Seal (Short)7. Oil Seal (Long)8. Bearing9. Water Pump Gear 10. Right Engine Cover 11. Cylinder Head 12. Cylinder13. Air Bleeder Bolt T1: 8.8 N·m (0.90 kgf·m, 78 in·lb)T2: 8.3 N·m (0.85 kgf·m,...

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 Cap relief pressure 108 ∼ 137 kPa (1.1 ∼ 1.4 kgf/cm², 16 ∼ 20 psi) Special Tools - Bearing Driver ...

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 thecoolant in accordance with the Periodic Maintenance Chart(see General Information chapter). WARNING To avoid burns, do not remove the radiator capor try to...

COOLING SYSTEM 3-5 Coolant Coolant Draining The coolant should be changed periodically to ensure long engine life. WARNING To avoid burns, do not remove the radiator cap ortry to change the coolant when the engine is stillhot. Wait until it cools down.Coolant on tires will make them slippery and can...

3-6 COOLING SYSTEM Coolant • Install the coolant drain plug. ○ Replace the gasket with a new one. Torque - Coolant Drain Plug (Water 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 clockwiseab...

COOLING SYSTEM 3-7 Coolant • Build up pressure in the system carefully until the pres-sure reaches 123 kPa (1.25 kgf/cm², 18 psi). • Watch the gauge for at least 6 seconds. If the pressureholds steady, the cooling system is all right. • Remove the pressure tester, replenish the coolant, andinstall t...

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 thendrain the coolant. • After assembling and filling the system with coolant, bleedany air from the system.

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

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 ∼ : • Remove the primary gear [B] (see Engine Right Sidechapter)....

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 HoseRadiator [E] Radiator Installation • Radiator installation is the reverse of removal. • Route the water and brea...

COOLING SYSTEM 3-13 Radiator Cap Inspection • Check the condition of the valve spring [B], and the topand 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 coolantto prevent pressure leaks. • Instal...

ENGINE TOP END 4-1 4 Engine Top End Table of Contents Exploded View ........................................................................................................................ 4-2 Specifications ...............................................................................................

4-2 ENGINE TOP END Exploded View 1. Spark Plug2. Cylinder Head3. Cylinder4. Piston Ring5. "1N" Mark6. "2N" Mark7. Piston8. "IN" Mark9. Piston Pin 10. Expansion Chamber 11. Rubber Seal 12. Gasket13. Muffler Body (KX65-A1 ∼ A2) T1: 25 N·m (2.5 kgf·m, 18 ft·lb)T2: 5.9 N·m (0.60 ...

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. • Remove the fuel tank (see Fuel System ...

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 highflash-point solvent. • Check for a crust of minerals and rust in the head waterjacket, and remove them if necessary. • Install a new cylinder he...

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 EndClutch Cable Lower EndMuffler Holding Springs • Remove the cylinder nuts [A]. • Lift off the cylinder [B], ...

ENGINE TOP END 4-7 Cylinder Piston Installation • Stuff a clean cloth into the crankcase opening around theconnecting rod so that no parts will fall into the crankcase. • Scrape off any carbon of the piston, then lightly polish thepiston with fine emery cloth. • Clean carbon and dirt out of the pist...

4-8 ENGINE TOP END Cylinder Cylinder Wear Inspection NOTE ○ Measure the cylinder inside diameter when the cylinderis cold (room or ambient temperature). • Visually Inspect the inside of the cylinder for scratchesand abnormal wear.If the cylinder is damaged or badly worn, replace it with anew one. • ...

ENGINE TOP END 4-9 Cylinder Piston Ring, Piston Ring Groove Inspection • Visually inspect the piston rings and the piston ringgrooves.If the rings are worn unevenly or damaged, they must bereplaced.If the piston ring grooves are worn unevenly or damaged,the piston must be replaced and fitted with ne...

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 thering. Also if the pin hole groove shows excessive wear,replace the piston. • Measure the diameter of the pi...

ENGINE TOP END 4-11 Muffler (Expansion Chamber) Muffler Removal • Remove: Right ShroudRight 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. • Remove the expansion chamber damper mounting bolts[...

ENGINE RIGHT SIDE 5-1 5 Engine Right Side Table of Contents Exploded View ........................................................................................................................ 5-2 Specifications .........................................................................................

ENGINE RIGHT SIDE 5-3 Exploded View 1. Clutch Lever2. Clutch Cable3. Release Lever Shaft4. Clutch Pusher5. Shim(s)6. Spring Plate Pusher7. Clutch Hub8. Clutch Wheel9. Friction Plate 10. Steel Plate 11. Clutch Housing 12. Sleeve13. Primary Gear14. Gear Set Levers15. Shift Shaft16. Kickstarter Idle Ge...

5-4 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Clutch Lever Free Play 2 ∼ 3 mm – – – Friction Plate Thickness 3.1 ∼ 3.3 mm 2.9 mm Steel Plate Thickness 1.47 ∼ 1.73 mm 1.37 mm Friction Plate Warp Not more than 0.2 mm 0.3 mm Steel Plate Warp Not more than 0.15 mm 0.3 mm Clutch Spring...

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 To avoid a serious burn, never touch the hot engineor exhaust chamber during clutch adjustment. Cl...

5-6 ENGINE RIGHT SIDE Clutch Cable • Free the clutch inner cable tip from the clutch releaselever. CAUTION Do not remove the clutch release shaft unless it isabsolutely necessary. If removed, release shaft oilseal must be replaced with a new one. • Pull the clutch cable out of the frame. Clutch Cabl...

ENGINE RIGHT SIDE 5-7 Right Engine Cover Right Engine Cover Removal • Drain the engine oil (see Engine Oil Change in the EngineBottom End/Transmission chapter). • Drain the coolant (see Coolant Draining in the CoolingSystem chapter). • Remove: Water Hose Lower EndsKick PedalClutch Cable Lower End (s...

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 coveris approx. 24° [F]. • S...

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 isabsolutely necessary. If removed, you must replacethe oil seal with a new on...

5-10 ENGINE RIGHT SIDE Clutch Clutch Removal • Remove the right engine cover (see Right Engine CoverRemoval). • Remove the clutch pusher [A], shim [B] (as required) andspring plate pusher [C]. • Remove the magneto cover. • Hold the magneto flywheel steady with flywheel & pulleyholder [A]. Specia...

ENGINE RIGHT SIDE 5-11 Clutch CAUTION If dry steel plates and friction plates are installed,apply transmission oil to the surfaces of each plateto avoid clutch plate seizure. ○ Install the friction plates and steel plates, starting with afriction plate and alternating them, finishing with a friction...

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 mustbe replaced. Clutch Spring Free Length Standard: 28.1 mm Service Limit: 2...

ENGINE RIGHT SIDE 5-13 External Shift Mechanism External Shift Mechanism Removal • Remove: Shift PedalRight Engine CoverClutch 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]. • Remove the ge...

5-14 ENGINE RIGHT SIDE Primary Gear Primary Gear Removal • Remove the right engine cover (see Right Engine CoverRemoval) • 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 • Put the water ...

ENGINE RIGHT SIDE 5-15 Primary Gear • Install the spring washer [A] with the concave side facingto 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...

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 thecrankcase. • Remove the ratchet guide bolt [B] and ratchet guide screw[C], take off the ratchet guide [D]. • Re...

ENGINE REMOVAL/INSTALLATION 6-1 6 Engine Removal/Installation Table of Contents Exploded View ........................................................................................................................ 6-2 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 ShroudsSide CoversSeatFuel TankWater HosesRadiatorsExpansion ChamberSpark PlugCarburet...

6-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Installation • Install the engine on the frame. • Before tightening the engine mounting nuts, measure theleft and right clearance [A] between the bosses [B] ofcrankcase and frame brackets [C] with thickness gauge. Clearance: Under 0....

ENGINE BOTTOM END/TRANSMISSION 7-1 7 Engine Bottom End/Transmission Table of Contents Exploded View ........................................................................................................................ 7-2 Specifications ...............................................................

ENGINE BOTTOM END/TRANSMISSION 7-3 Exploded View 1. Crankshaft Assembly2. Magneto Stator3. Magneto Flywheel4. Left Crankcase5. Right Crankcase6. Drive Shaft7. Output Shaft8. Engine Sprocket9. Shift Rod 10. Shift Fork 11. Operating Plate 12. Shift Drum13. Shift Shaft14. Shift Pedal15. KX65-A1 ∼ A5 16...

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 leveland change the oil periodically. WARNING Motorcycle operation with insufficient, deteri-orated, or contaminated transmission oi...

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 engineoil drain plug with the gasket, and tighten it. Torque - Engine Oil Drain P...

ENGINE BOTTOM END/TRANSMISSION 7-7 Crankcase Crankcase Splitting • Remove the engine (see the Engine Removal/Installationchapter). • Set the engine on a clean surface while parts are beingremoved. • Remove: Magneto CoverOutput Shaft Sleeve [A] and O-ring [B] Cylinder Head (see Engine Top End Chapter...

7-8 ENGINE BOTTOM END/TRANSMISSION Crankcase • Pull out the shift rods [A]. • Disengage the shift fork guide pins from the shift drumgrooves. • Take off the shift drum [B] • Remove the shift forks [C] from the transmission gears. • Take out the drive shaft [D] and output shaft [E] togetherwith their...

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. ○ If the cra...

7-10 ENGINE BOTTOM END/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the transmission shafts (see Transmission ShaftRemoval). • Using a press, remove the crankshaft from the rightcrankcase. ○ If the bearings stay on the crankshaf...

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 Vblocks, and place a dial gauge against the connecting rodbig end. • Push the connecting rod first towards the gauge and thenin the...

7-12 ENGINE BOTTOM END/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Alignment Inspection • In the case of horizontal misalignment, which is the mostcommon, strike the projecting rim of the flywheel with aplastic, soft lead, or brass hammer as indicated in thefigure. • Recheck the runout with a...

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 forkguide pins from the shift drum grooves. • Remove the shift drum [B] • Remove the shift forks [C] from the transmission gears. • T...

7-14 ENGINE BOTTOM END/TRANSMISSION Transmission • The output shaft gears can be identified by size; thelargest diameter gear is 1st gear, and the smallest is6th. Be sure that all parts are put back in the correctsequence and facing the proper direction, and that allcirclips are properly in place. [...

ENGINE BOTTOM END/TRANSMISSION 7-15 Transmission • Install the shift drum. • Fit the shift fork guide pins into the corresponding shiftdrum grooves. • Apply a little transmission oil to the shift rods, and slidethem into the shift forks. • Holding the shift drum with the suitable tool and tightenthe...

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. Thegear must be replaced if the teeth are badly damaged.When gear is repaired or replaced, the driving gear shouldal...

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 wheelthe ground. • Remove the cotter pin [A] • Unscrew the axle nut [B]. • Remove the axle [A], ...

WHEELS/TIRES 8-5 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut donot align with the cotter pin hole in the axle, tighten thenut clockwise [B] up to next alignment. ○ It should be within 30 degree. ○ Loosen once and tighten again when the s...

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 rearhub. CAUTION Do not lay the wheel on the ground with the discfacing ...

WHEELS/TIRES 8-7 Wheels (Rims) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in the nut donot align with the cotter pin hole in the axle, tighten thenut clockwise [B] up to next alignment. ○ It should be within 30 degree. ○ Loosen once and tighten again when the s...

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 dialgauge.If the rim runout exceeds the service limit, check the hubbearings. Replace them if they are damaged.If the problem is not ...

WHEELS/TIRES 8-9 Tires 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 track conditions andrider preference, but do not stray too far from the recom-mended pressure. Track Condition Tire P...

8-10 WHEELS/TIRES Tires Tire Removal CAUTION Do not lay the wheel on the ground with the discfacing down. This can damage or warp the disc.Place blocks under the wheel so the disc does nottouch the ground. • Remove the wheel from the motorcycle (see Wheels Re-moval). • To maintain wheel balance, mar...

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 therim flange and tire beads. • Position the tire on the rim so that the valve [A] is at the tirebalance mark [B] (the ch...

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 discfacing down. This can damage or warp the disc.Place blocks under the wheel so that the disc doesnot touch the ground. • Remove the oil seals and circlip....

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:...

FINAL DRIVE 9-1 9 Final Drive Table of Contents Exploded View ........................................................................................................................ 9-2 Specifications .....................................................................................................

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 itappears 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 thetightest position, and readjust if necessary. WARNING If the axle nut is not securely tightened, or the cotterpin is not installed, an unsafe riding condition mayresult. NO...

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] ofthe chain from the pin center of the 1st pin to the pin centerof the 21st pin. Since the chain may wear unevenly, takemeasurem...

FINAL DRIVE 9-7 Drive Chain Drive Chain Installation • Fit the drive chain back onto the sprockets with the endsat 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]. • Ad...

9-8 FINAL DRIVE Sprockets Engine Sprocket Removal • Remove: Magneto CoverDrive 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 • Replace the circlip with a new one. • Inst...

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 theteeth as shown and rotate [C] the rear wheel to measurethe sprocket runout (warp). The differenc...

BRAKES 10-1 10 Brakes Table of Contents Exploded View ........................................................................................................................ 10-2 Specifications ............................................................................................................

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. • After adjustment, tighten the locknut. WARNING Always mai...

10-6 BRAKES Brake Lever, Brake Pedal • Remove the brake pedal mounting bolt [A] and take offthe 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. • Apply high temperature grease to the shaft portion of th...

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. Do not mix two types and brands of fluid for use in the b...

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 fluidreservoirs. • Check the brake fluid level in the front brake reservoir [A]. NOTE ○ Hold the reservoir horizontal when checking brake flui...

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 pedalis transmitted directly to the caliper for braking action. Air,however, is easily compressed. When air enters the brakelines, brake lever...

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 brakingpower, 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]. • Remove the banjo bolt and take off the brake hose fromthe caliper [C]. • If the caliper is to be disassembled after removal and ifcompressed air is ...

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 andcover. • Using compressed air, remove the piston(s). ○ Cover the caliper opening with a clean, he...

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 aredamaged. • Apply a thin coat of silicone grease to the caliper holdershafts and holder holes (PBC is a special high tempera-ture, water-resistant grease). • In...

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. Brake Pad Installation • Push the caliper pistons in...

10-16 BRAKES Master Cylinder CAUTION Brake fluid quickly ruins painted or plastic sur-faces; any spilled fluid should be completely wipedup immediately. Front Master Cylinder Removal • Remove the banjo bolt [A] to disconnect the upper brakehose from the master cylinder (see Brake Hose Re-moval/Insta...

BRAKES 10-17 Master Cylinder Rear Master Cylinder Removal • Remove the right side cover and the reservoir mountingbolt [A]. • Remove the cotter pin [B]. • Pull off the joint pin [C] with washer. NOTE ○ Pull off the joint pin while pressing down the brakepedal. • Unscrew the brake hose banjo bolt [D]...

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 • Pull out the push rod with the piston stop [D]. • Take off the p...

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 theinner wall of each master cylinder [A] and on the outsideof each piston [B].If a master cylinder or piston shows a...

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] whereit has worn the most.Replace the disc if it has worn past the service limit. Thickness Standard: Front 2.80 ∼ 3.20...

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 wipedup immediately with watered cloth. • When removing the brake hose, take care not to spill thebrake fluid on the painted or plastic parts...

SUSPENSION 11-1 11 Suspension Table of Contents Exploded View ........................................................................................................................ 11-2 Specifications ....................................................................................................

SUSPENSION 11-7 Front Fork The front fork should always be adjusted for the rider’s weight and track conditions by using one or more of thefollowing methods. ○ Oil level adjustment - The effects of higher or lower forkoil level are only felt during the final 100 mm of fork travel.A higher oil level ...

11-8 SUSPENSION Front Fork KX65-A3 ∼ • Remove: Number PlateHandlebar AssemblyFront Fork Top Plug [A]Fork Spring [B]Fork Spring Seat [C] • Slowly compress the front fork fully by pushing up theouter tubes [A] using a jack or other suitable means underthe front wheel. • Place a stand or other suitable...

11-10 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 distance from the topof the inner tube to the oil. Special Tool - Fork Oil Level Gauge: 57001-1290 Oil Level (fully compressed, without spring) Standa...

SUSPENSION 11-11 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 is10 mm up [B] with the upper surface [C] of the steeringstem head. • Install the fork so that the top end [A] of the inner t...

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 innertube from the outer tube. Special Tool - Fork Outer Tube Weight: 57001-1218 ○ Holding the inner tube b...

SUSPENSION 11-13 Front Fork Front Fork Assembly (each fork) • Assembly is the reverse of disassembly. • Replace the following parts removed with a new one. Guide BushesOil SealBottom Allen Bolt Gasket • Inspect the following and replace them with new ones ifdamaged. Inner Tube (see Inner Tube Inspec...

11-14 SUSPENSION Front Fork Inner Tube Inspection • Visually inspect the inner tube [A], repair any damage. • Nick or rust damage can sometimes be repaired by usinga wet-stone to remove sharp edges or raised areas whichcause seal damage.If the damage is not repairable, replace the inner tube.Since d...

SUSPENSION 11-15 Rear Suspension (Uni-Trak) Rear Shock Absorber The rear suspension system of this motorcycle is Uni-trak. It consists of a rear shock absorber, swingarm, tie-rod androcker arm. To suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spri...

11-16 SUSPENSION Rear Suspension (Uni-Trak) • Using the hook wrench [A], turn the adjusting nut [B] asrequired. Turning the adjusting nut downward marks thespring action harder and upward softer. Special Tool - Hook Wrench: 57001-1101 Spring Preload Adjustment(Adjusting nut position [A] from the cen...

11-18 SUSPENSION Rear Suspension (Uni-Trak) • Remove the rear shock absorber from the vise. • Remove the stopper ring [A]. • Remove the spring seat [B] from the shock absorber andlift off the spring [C]. • Install the spring guide. • Adjust the spring preload (see Spring Preload Adjust-ment). • Inst...

SUSPENSION 11-19 Swingarm Swingarm Removal • Place the jack under the frame so that the rear wheel isoff the ground. Special Tool - Jack: 57001-1238 • Remove the rear wheel (see Wheels/Tires chapter). • Remove the brake pedal [A]. • Remove the tie-rod rear mounting bolt [B]. CAUTION When pulling out...

11-20 SUSPENSION Swingarm Swingarm Bearing Installation • Replace the needle bearings, dust seals and oil seals withnew ones. • Apply plenty of grease to the dust seals, oil seals andneedle bearings. NOTE ○ Install the needle bearings so that the manufacturer’smarks face out. Special Tool - Bearing ...

SUSPENSION 11-21 Tie-rod, Rocker Arm Tie-rod Removal • Using the jack under the frame, raise the rear wheel offthe ground. Special Tool - Jack: 57001-1238 • Remove the tie-rod front mounting bolt [A]. CAUTION When pulling out the mounting bolts, lift the rearwheel slightly. Forcing or tapping on a b...

11-22 SUSPENSION Tie-rod, Rocker Arm Rocker Arm Installation • Apply plenty of grease to the inside of the rocker armholes, needle bearings, oil seals and grease seals out-side of the sleeve. • Install the needle bearing [A], grease seals [B] and oilseals [C] position as shown. • Tighten the followi...

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 offthe ground. Special Tool - Jack: 57001-1238 • Push and pull on the swingarm [A], up and down, to checkfor...

STEERING 12-1 12 Steering Table of Contents Exploded View ........................................................................................................................ 12-2 Specifications ........................................................................................................

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, alternatelynudge each end of the handlebar. The front wheel shouldswing fully left and right from the force of gravity un...

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 FenderHandlebar (see Handlebar Removal)Front Fo...

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 thehead pipe using the press shaft [A] and the drivers [B]. Special Tools - Head Pipe Outer Race Press Shaft: 57001 -1075 Head Pipe O...

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 andlower tapered rollers in the cages, and wipe the upperand lower outer races, which are press-fitted into theframe head pipe, clean...

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 handlebargrip [A]. • Install the front master cyli...

ELECTRICAL SYSTEM 13-1 13 Electrical System Table of Contents Wiring Diagram ....................................................................................................................... 13-2 Exploded View .......................................................................................

ELECTRICAL SYSTEM 13-3 Exploded View 1. Magneto Cover2. Magneto Flywheel3. Stator4. CDI Unit5. Ignition Coil6. Spark Plug Cap7. Spark Plug8. Engine Stop Button9. 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...

13-4 ELECTRICAL SYSTEM Specifications Item Standard Magneto Stator coil resistance in the text Ignition System Ignition Timing: 20.5° BTDC @6 000 r/min (rpm)20.5° BTDC @7 100 r/min (rpm) (KX65A6F ∼ ) Ignition Coil: 3 Needle Arcing Distance 7 mm or more Primary Winding Resistance 0.31 Ω ±15% (at 20°C...

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, aswith a hammer, or allowed to fall on a hard surface. Sucha shock to the par...

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 ...

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] onthe magneto stator plate is aligned with the mark [B] onthe crankcase.If the marks are not aligned, loosen the magneto statorplate mounting screws ...

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 flywhee...

ELECTRICAL SYSTEM 13-9 Flywheel Magneto • Using a high flash-point solvent, clean off any oil or dirtthat 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...

13-10 ELECTRICAL SYSTEM Flywheel Magneto • To check the stator coil resistance as follows. ○ Connect the hand tester to the terminals of the harnessconnector [A] as shown in the table 2. ○ Note the readings. Table 2 Stator Coil Resistance Connections Tester Range Tester (+) Tester (–) to Reading × 1...

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, orhigh tension lead while the engine is running, oryou could receive a severe electrical shock. Crankshaft Sensor Installation (KX65A6...

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. • Connect the black ...

ELECTRICAL SYSTEM 13-13 Ignition System WARNING To avoid extremely high voltage shocks, do nottouch the coil or lead. If the distance reading is less than the specified value, theignition coil or spark plug cap is defective. 3 Needle Arcing Distance Standard: 7 mm or more • To determine which part i...

13-14 ELECTRICAL SYSTEM Ignition System Spark Plug Cleaning and Inspection • 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 mayalso be cleaned using a high flash-point solvent and a wireb...

ELECTRICAL SYSTEM 13-15 Ignition System Ignition Coil Primary Peak Voltage Check • Remove: ShroudsSide CoversSeatFuel 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. NOTE ○ Measure the voltage with eac...

ELECTRICAL SYSTEM 13-17 Ignition System Exciter (Stator) Coil Peak Voltage Check • Disconnect the connector of the harness from the CDIUnit. • To check the peak voltage, do the following procedures. NOTE ○ Measure the voltage with each lead connected cor-rectly. The correct value may not be obtained...

APPENDIX 14-1 14 Appendix Table of Contents Troubleshooting Guide ........................................................................................................... 14-2 General Lubrication ........................................................................................................

14-2 APPENDIX Troubleshooting Guide NOTE ○ This is not an exhaustive list, giving everypossible cause for each problem listed. Itis meant simply as a rough guide to assistthe troubleshooting for some of the morecommon difficulties. Engine Doesn’t Start, Starting Difficulty: Engine won’t turn over: C...

APPENDIX 14-3 Troubleshooting Guide Flywheel magneto damagedIgnition coil lead or CDI Unit lead not in good contact Fuel/air mixture incorrect: Main jet clogged or wrong sizeJet needle or needle jet wornJet needle clip in wrong positionFloat level too high or too lowAir jet or air passage cloggedAir...

APPENDIX 14-5 Troubleshooting Guide Wheel misalignmentSwingarm bent or twistedSwingarm pivot shaft runout excessiveSteering maladjustedSteering stem bentFront fork leg bentRight/left front fork oil level uneven Shock absorption unsatisfactory: (Too hard)Front fork oil excessiveFront fork oil viscosi...

14-6 APPENDIX General Lubrication Lubrication (Periodic Maintenance) • Before lubricating each part, clean off any rusty spots withrust 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 un...

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 goodcondition. NOTE ○ For the engine fasteners, check the tightness of themwhen the engine is cold (at room temperature)...

MODEL APPLICATION Year Model Beginning Frame No. 2000 KX65-A1 JKBKEAC □ YA000001 or JKAKX065AAA000001 2001 KX65-A2 JKBKXEAC □ 1A009001 or JKBKX065AAA009001 2002 KX65-A3 JKBKXEAC □ 2A016001 or JKBKX065AAA016001 2003 KX65-A4 JKBKXEAC □ 3A027001 or JKBKX065AAA027001 2004 KX65-A5 JKBKXEAC □ 4A036001 or ...