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Manual Kawasaki KX65 (2010)

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  • Kawasaki KX65 (2010) - page 1

    KX65 Motorcycle Service Manual ...

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    This quick refe rence guide will assist you in locating a desired topic or pro - cedure. •Bend the pag es back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific to pic required. Quick Referen ...

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    KX65 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality A ssurance Division/Consumer Products & Machinery Company/Kawasa ...

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    LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct c ...

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    Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However , it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop proce- dures must be ...

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    GENERAL INFORMA TION 1-1 1 General Information T able of Contents Before Servicing ................................................................................................................ ..... 1-2 Model Identification............................................................................................................ ..... 1-5 Gener ...

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    1-2 GENERAL INFORMA TION Before Servicing Before starting to perform an inspection service or c arry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below . T o facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descr iptions have been included in each chapter wherever ...

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    GENERAL INFORMA TION 1-3 Before Servicing (1 1) Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12) Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely ne cessary . R ...

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    1-4 GENERAL INFORMA TION Before Servicing (19) Inspection When parts have been disassembled, visually ins pect 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 W arp Bent Dent Scratch Wear Color change Deterioration Seizure (20) Specific ...

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    GENERAL INFORMA TION 1-5 Model Identification KX65-A1 Left Side View KX65-A1 Right Side Vi ew ...

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    1-6 GENERAL INFORMA TION General Specifications Items KX65-A1 ∼ A2 KX65-A3 ∼ A6, A6F ∼ 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 11 1 0m m 1 120 mm Road Clearance 270 mm (KX65-A1), 280 mm (KX65-A2) 305 mm Seat Heigh ...

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    GENERAL INFORMA TION 1-7 General Specifications Items KX65-A1 ∼ A2 KX65-A3 ∼ A6, A6F ∼ ABF Drive T rain Primary Reduction System: Ty p e Gear ← Reduction Ratio 3.500 (77/22) ← Clutch T ype Wet, multi disc ← T ransmission: Ty p e 6-speed, constant mesh, return shift ← Gear Ratios: 1st 2.846 (37/13) ← 2nd 2.125 (34/16) ← 3rd 1.722 ( ...

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    1-8 GENERAL INFORMA TION General Specifications Items KX65-A1 ∼ A2 KX65-A3 ∼ A6, A6F ∼ ABF Brake T ype: 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 . US: United States Model ...

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    GENERAL INFORMA TION 1-9 Periodic Maintenance Chart The maintenance must be done in accordance with t his chart to keep the motorcycle in good running condition. FREQUENCY OPERA TION 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 Clutch - adjust • Clutch and friction ...

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

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    GENERAL INFORMA TION 1-1 1 T orque and Locking Agent T i ghten all bolts and nuts to th e 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 requ ...

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    1-12 GENERAL INFORMA TION T orque and L ocking Agent T orque Fastener N·m kgf·m ft·lb Remarks Engine Removal/Installation Engine Mounting Nuts 25 2.5 18 Engine Mounting Nuts (KX65-A3 ∼ ) 29 3.0 21 Swing Arm Pivot Shaft Nut 69 7.0 51 Engine Bottom End/T ransmission Cylinder Stud ––– L (Planted Side) Crankcase Bolts 8.8 0.90 78 in·lb Shif ...

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    GENERAL INFORMA TION 1-13 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Rocker Arm Pivot Nut 83 8.5 61 Caliper Mounting Bolts 25 2.5 18 Rear Frame Mounting Bolts 34 3.5 25 Steering Steering Stem Head Nut 44 4.5 33 Steering Stem Nut 2.9 0.30 26 in·lb Handlebar Clamp Bolts 25 2.5 18 Clutch Lever Clamp Bolts 8.8 0.90 78 in·lb ...

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    1-14 GENERAL INFORMA TION Special T ools and S ealants Bearing Puller Adapt er: 57001-136 Steering Ste m Bearing Driver: 57001-137 Inside Circ lip Pliers: 57001-143 Outside Circlip Pli ers: 57001-144 Bearing Puller: 57001-158 Fork Cylinder Holder Handle: 57001-183 Flywheel Puller , M12 × 1.75: 57001-252 Piston Pin Puller Assembly: 57001-910 Fork C ...

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    GENERAL INFORMA TION 1-15 Special T ools and Sealant s Rim Protector: 57001-106 3 Bead Breaker Assembly: 57001-107 2 Head Pipe Outer Race Press Shaft: 57001-107 5 Steering Stem Bearing Drive r Adapter , 29.7: 57001-109 2 Steering Stem Nut W rench: 57001-1 100 Hook Wrench R3 7.5, R42: 57001-1 101 Head Pipe Outer Race Driver , 46.5: 57001-1 106 Head ...

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    1-16 GENERAL INFORMA TION Special T ools and S ealants Front Fork Oil Seal Driver: 57001-1219 Jack: 57001-1238 Fork Oil Level Gauge: 57001-1290 Crankcase Splitti ng T ool Assembly: 57001-1362 Hand T ester: 57001-1394 Peak V oltage Adapter: 57001-1415 Crank Shaft Jig: 57001-1439 Graduated Cyli nder & T ube: 57001-1584 Flywheel & Pulley Holde ...

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    GENERAL INFORMA TION 1-17 Special T ools and Sealant s Liquid Gasket, TB121 1: 56019-120 Liquid Gasket, TB1 105B: 92104-002 ...

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    1-18 GENERAL INFORMA TION Cable, Wire and Hose Routing 1. Throttle Cable 2. Carburetor 3. Breather Hose 4. Air V ent Hose 5. Overflow Hose 6. The hoses are passed from the left side of the engine through the clamp in order of the air vent hose, the overflow hose and the breather hose as shown in figure. 7. CDI Unit (KX65-A1 ∼ A6) 8. Clamp 9. Rubb ...

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    GENERAL INFORMA TION 1-19 Cable, Wire and Hose Routing 1. Breather Hose 2. Run the throttle cable under the breather hose. 3. Radiator 4. CDI Unit (KX65 -A1 ∼ A6) 5. Clamp (KX65-A1 ∼ A6) 6. Throttle Cable 7. Clamp as shown in figure. (Be sure the clamp screw position is inside.) 8. Clamp as shown in figure. 9. Cylinder Head 10. Cylinder 1 1. W ...

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    1-20 GENERAL INFORMA TION Cable, Wire and Hose Routing 1. Clamp 2. CDI Unit (KX65-A1 ∼ A6) 3. Band 4. Clamp the magneto leads at the upper part of the left on t he carburetor holder . 5. Magneto Leads 6. Shift Pedal 7. 19 ±10 mm (Shift Pedal Position) 8. Engine Stop Button Lead 9. Ignition Coil 10. Engine Stop Button Lead Ground 1 1. CDI Unit Gr ...

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    GENERAL INFORMA TION 1-21 Cable, Wire and Hose Routing 1. Front Brake Reservoir 2. Banjo Bolts 3. Clamp 4. Front Brake Disk 5. Bleed V alves 6. Front Brake Caliper 7. Rear Brake Caliper 8. Rear Brake Disk 9. Rear Brake Reservoir 10. Rear Brake Master Cylinder 1 1. Bend the cotter pin end by along the joint pin. 12. White paint mark ...

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    1-22 GENERAL INFORMA TION Cable, Wire and Hose Routing KX65A6F ∼ 1. Throttle Cable 2. Clutch Cable 3. Band 4. Engine Stop Button Lead 5. Clamp 6. CDI unit 7. Band 8. CDI unit Gro und Lead 9. Ignition Coil Primary Lead 10. Ignition Coil Grou nd Lead 1 1. Ignition Coil 12. Band 13. Clamp the Magnet o Lead 14. KX65A6F ∼ A8F 15. KX65A9F ∼ ...

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    FUEL SYSTEM 2-1 2 Fuel System T able of Contents Exploded View ................................................................................................................... ..... 2-2 Specifications ...................................................................................................... ........... ........ 2-4 Throttle Grip and ...

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    2-2 FUEL SYSTEM Exploded View 1. Throttle Cable 2. Throttle G rip 3. Carburetor Holder 4. Carburetor Cap 5. Spring 6. Retainer 7. Jet Needle Clip 8. Jet Needle 9. Throttle V alve 10. Choke Knob 1 1. Idle Adjusting Screw 12. Spring 13. Air Screw 14. Slow Jet 15. Float V alve Needle 16. Main Jet 17. Float 18. Reed V alve T1: 8.8 N·m (0.90 kgf·m, 78 ...

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    FUEL SYSTEM 2-3 Exploded View 1. Fuel T ank Cap 2. Fuel T ank 3. Fuel T ap 4. Air Cleaner Housing 5. Element 6. Frame 7. Holder 8. Air Cleaner Duct 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. O: High-quality foam-air filter oil ...

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    2-4 FUEL SYSTEM Specifications Standard Item KX65-A1 ∼ A2 KX65-A3 ∼ Service Limit Throttle Grip Free Play and Cable 2 ∼ 3m m ← ––– Carburetor Make/T ype MIKUNI VM24SS ← ––– Main Jet #230 #190 ––– Throttle V alve Cutaway #2 #1.5 ––– Jet Needle 5HS59 5G SP68 ––– Jet Needle Clip Position 3rd groove from the top ...

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    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 ...

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    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 . WA R N I N G Operation with incorrectly routed or improperly ad- justed cables could result in ...

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    FUEL SYSTEM 2-7 Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear , maladjustment, or improper fuel level in the float chamber . A dirty o ...

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    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. • Remove the drain plug from the bottom of the floa ...

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    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 leve l. Float Height Standard : 2 1 . 1± 1m m NOTE ○ Float height [A] is the distan ...

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    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 othe ...

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    FUEL SYSTEM 2-1 1 Carburetor • T urn the fuel tap to the ON position, and check for fuel leakage from the carburetor . WA R N I N G Fuel spilled from the carburetor is hazardous. • Adjust the following items if necessary: Throttle Cable (see this chapter) Idle Speed (see this chapter) Fuel Inspection WA R N I N G Gasoline is extremely flammable ...

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    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) • Disassembl ...

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    FUEL SYSTEM 2-13 Carburetor Carburetor Clea ning WA R N I N G 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. Do not use gasol ...

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    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 pressur ...

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    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]. • Remove the air clea ner housing [E]. Air Cleaner Housing Installation • Installation is the ...

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    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. ○ After riding through rain or on muddy roads, the element should be cleaned immediately . ...

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    FUEL SYSTEM 2-17 Fuel T ank Fuel T a nk Removal WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • Remove: Radiator Shrouds Seat ? ...

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    2-18 FUEL SYSTEM Fuel T ank Fuel T ap Ins pection • 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. Replace the fuel tap. If the fuel tap leaks, or allows fuel to flow when ...

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    FUEL SYSTEM 2-19 Reed V alve Reed V alve Re moval • Remove the carburetor holder mounting bolts and carbu- retor holder [A]. • Remove the reed valve [B] out of the cylinder . Reed V alve Installatio n • 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 th ...

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    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. Replace the fuel hose if any frayin ...

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    COOLING SYSTEM 3-1 3 Cooling System T able of Contents Exploded View ................................................................................................................... ..... 3-2 Specifications ...................................................................................................... ........... ........ 3-3 Coolant .... ...

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    3-2 COOLING SYSTEM Exploded View 1. Radiator 2. Radiator Cap 3. W ater Pump Cover 4. Drain Plug 5. Impeller 6. Oil Seal (Short) 7. Oil Seal (Long) 8. Bearing 9. W ater Pump Gear 10. Right Engine Cover 1 1. Cylinder Head 12. Cylinder 13. Air Bleeder Bolt T1: 8.8 N·m (0.90 kgf·m, 78 in ·lb) T2: 8.3 N·m (0.85 kgf·m, 73 in ·lb) T3: 5.9 N·m (0.60 ...

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    COOLING SYSTEM 3-3 Specifications Item Standard Coolant Ty p e Permanent type antifreeze for aluminum engines and radiators Color Green Mixed ratio Soft water 50%, coolant 50% T otal amount 0.4 L Radiator Cap relief pressure 108 ∼ 137 kPa (1.1 ∼ 1.4 kgf/cm², 16 ∼ 20 psi) Special T ools - Bearing Driver Set: 57001- 1 129 Outside Circlip Pli e ...

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    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). WA R N I N G Hot engine coolant can cause serious burns. T o avoid burns, do not remove the radiator cap or tr ...

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    COOLING SYSTEM 3-5 Coolant Coolant Dra ining The coolant should be changed periodically to ensure long engine life. WA R N I N G 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; allow it cool completely . Immediately wipe any spi ...

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    3-6 COOLING SYSTEM Coolant • Fill the radiator up to the bottom of the radiator filler neck [B] with coolant [A], and install th e 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 . The radiator cap must be installed in two steps. First turn the cap clockwise t ...

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    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 ef fi- cien ...

  • Kawasaki KX65 (2010) - page 58

    3-8 COOLING SYSTEM Disassembly and Assembly Precautions • Prior to disassembly of cooling system parts (radiator , pump, etc), wait until the coolant cools down, and then drain the coolant. • After assembling and filling t he system with coolant, bleed any air from the system. ...

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    COOLING SYSTEM 3-9 W ater 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], a nd remove the water pump cover . Water Pump Cover Installation • Replace the pump cover gasket with a new one. ? ...

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    3-10 COOLING SYSTEM Wa t e r P u m p 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 T ool - Outside Circlip Pliers: 57001-144 KX65A6F ∼ : • Remove the primary gear [B] (see Engine Right Side chapter). • Pull out the water pump shaft ...

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    COOLING SYSTEM 3- 1 1 W ater Pump • Press the ball bearing [A] into the hole until the bearing is bottomed against the step [B]. Special T ools - Bearing Driver Set: 57001-1 129 • Apply plenty of high temperature grease to the oil seal lip s [D]. • Set the oil seal (thick) so that dual lips side face outward and set the oil seal (thin) so tha ...

  • Kawasaki KX65 (2010) - page 62

    3-12 COOLING SYSTEM Radiator Radiator Removal • Drain the coolant (see Coolant Draining). • Remove: Left Shroud [A] Wa t e r H o s e [ B ] Radiator Mounting Bolts [C] Radiator Screen [D] Breather Hose Radiator [E] Radiator Installation • Radiator installation is the reverse of removal. • Route the water and breather hoses correctly . T orqu ...

  • Kawasaki KX65 (2010) - page 63

    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 rad iator 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. • Install the cap [A] on a cooling system pressu ...

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    ENGINE TOP END 4-1 4 Engine T op End T able of Contents Exploded View ................................................................................................................... ..... 4-2 Specifications ...................................................................................................... ........... ........ 4-3 Cylinder He ...

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    4-2 ENGINE T OP END Exploded View 1. Spark Plug 2. Cylinder Head 3. Cylinder 4. Piston Ring 5. "1N" Mark 6. "2N" Mark 7. Piston 8. "IN" Mark 9. Piston Pin 10. Expansion Chamber 1 1. Rubber Seal 12. Gasket 13. Muffler Body (KX65-A1 ∼ A2) T1: 25 N·m (2.5 kgf·m, 18 ft·lb) T2: 5.9 N·m (0.60 kgf·m, 52 in ·lb) T3: 26 ...

  • Kawasaki KX65 (2010) - page 67

    ENGINE T OP 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 Cylinder Inside Diameter (15 mm below from the Cylinder T op End) 44.500 ∼ 44.515 mm 44.6 4 mm Piston Diameter ...

  • Kawasaki KX65 (2010) - page 68

    4-4 ENGINE T OP 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 chapter). • Remove the spark plug, an ...

  • Kawasaki KX65 (2010) - page 69

    ENGINE T OP 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 . • Install a new cylinder head gasket [A] so that its “UP” mar ...

  • Kawasaki KX65 (2010) - page 70

    4-6 ENGINE T OP END Cylinder Cylinder Removal • Drain the coolant (see Cooling System chapter). • Remove: Cylinder Head (see this chapter) Carburetor (see Fuel System chapter) W ater Hose Upper End Clutch Cable Lower End Muffler Holding Springs • Remove the cylinder nuts [A]. • Lift off the cylinder [B], and remove the cylinder base gas- ke ...

  • Kawasaki KX65 (2010) - page 71

    ENGINE T OP END 4-7 Cylinder Piston Installation • Stuff a clean cloth i nto 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. • Clean carbon and dirt out of the piston ring groove using a suitable tool. NO ...

  • Kawasaki KX65 (2010) - page 72

    4-8 ENGINE T OP 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. • Since there is a difference in cylinde ...

  • Kawasaki KX65 (2010) - page 73

    ENGINE T OP 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. • Check for uneven groove wear ...

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    4-10 ENGINE T OP 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. • Measure the diameter of the piston pin [B] with a microm- eter . If the ...

  • Kawasaki KX65 (2010) - page 75

    ENGINE TOP END 4-1 1 Muffler (Expansion Chamber) Muffler Removal • Remove: Right Shroud Right Side Cover • Remove the muf fler mounting bolts [B] and pull the muf fler [A] off toward the rear . • Remove the springs [A] holding the exhaust pipe holding . • Remove the expansion chamber damper mounting bolts [A], and pull of f the expansion ch ...

  • Kawasaki KX65 (2010) - page 76

    4-12 ENGINE T OP END Muffler (Expansion Chamber) • Unscrew the inner pipe mounting bolts [A]. • Pull the inner pipe [B] from the muf fler body . • Pull off the old muf fler baffle, and install the new muffler baffle [A] into the muf fler body . • Apply silicone sealant to the circumference [B] of the inner pipe. • Apply a non-permanent lo ...

  • Kawasaki KX65 (2010) - page 77

    ENGINE RIGHT SIDE 5-1 5 Engine Right Side T able of Contents Exploded View ................................................................................................................... ..... 5-2 Specifications ...................................................................................................... ........... ........ 5-4 Clutch ...

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    5-2 ENGINE RIGHT SIDE Exploded View ...

  • Kawasaki KX65 (2010) - page 79

    ENGINE RIGHT SIDE 5-3 Exploded View 1. Clutch Lever 2. Clutch Cable 3. Release Lever Shaft 4. Clutch Pusher 5. Shim(s) 6. Spring Plate Pusher 7. Clutch Hub 8. Clutch Wheel 9. Friction Plate 10. Steel Plate 1 1. Clutch Housing 12. Sleeve 13. Primary Gear 14. Gear Set Levers 15. Shift Shaft 16. Kickstarter Idle Gear 17. Ratchet Gear 18. Kick Gear 19. ...

  • Kawasaki KX65 (2010) - page 80

    5-4 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Clutch Lever Free Play 8 ∼ 13 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 W arp Not more than 0.15 mm 0.3 mm Clutch Spring Free Length 28.1 mm 26.7 mm Friction ...

  • Kawasaki KX65 (2010) - page 81

    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 adjuste d in accor- dance with the Periodic Maintenance Chart. WA R N I N G The engine and exhaust system get extremely hot during normal operation and can cause serious burns. Never touch the engine or exhaust pipe d ...

  • Kawasaki KX65 (2010) - page 82

    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 . • Loosen the knurled locknut [A] at the clutch lever , and screw in the adjuster [B]. • Line up the slots [C] in the clutch lever , ...

  • Kawasaki KX65 (2010) - page 83

    ENGINE RIGHT SIDE 5-7 Right Engine Cover Right Engine Cover Removal • Drain the engine oil (see Engine Oil Change in the Engine Bottom End/T ransmission chapter). • Drain the coolant (see Coolant Draining in the Cooling System chapter). • Remove: W ater Hose Lower Ends Kick Pedal Clutch Cable Lower End (see this chapter) Brake Pedal W ater Pu ...

  • Kawasaki KX65 (2010) - 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. 24° [F]. • Stick the new right engine cover gasket i ...

  • Kawasaki KX65 (2010) - page 85

    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. • Refer to the cooling system chapter ...

  • Kawasaki KX65 (2010) - page 86

    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]. Special T ool - Flywheel & Pulley Holde ...

  • Kawasaki KX65 (2010) - page 87

    ENGINE RIGHT SIDE 5-1 1 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. ○ Install the hub nut and clutch sp ...

  • Kawasaki KX65 (2010) - page 88

    5-12 ENGINE RIGHT SIDE Clutch Spring Free Length Measureme nt • Since the spring [A] becomes shorter as it weakens, check its free length to determine its condition. If any of the springs is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 28.1 mm Service Limit: 26.7 mm Friction Plate/Clutch Housing Clearan ...

  • Kawasaki KX65 (2010) - page 89

    ENGINE RIGHT SIDE 5-13 External Shift Mechanism External Shift Mechani sm 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]. • Remove the gear set lever spring [C]. • Remove t ...

  • Kawasaki KX65 (2010) - page 90

    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 T ools - Outside Circlip Pli ers: 57001-144 Primary Gear Installation • Put the water pump drive gear [A] and primary gear [B] ...

  • Kawasaki KX65 (2010) - page 91

    ENGINE RIGHT SIDE 5-15 Primary Gear • Install the spring washer [A] with the concave side facing to the inward. • T emporarily tighten the primary gear nut [B]. • T ighten the primary gear nut ○ Primary gear nut is left-hand threads. T orque - Pr imary Gear Nut: 49 N·m (5.0 kgf·m, 36 ft·l b) Special T ools - Flywheel & Pulley Holder: ...

  • Kawasaki KX65 (2010) - page 92

    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]. • Remove the kickstarter assembly [E]. Kick ...

  • Kawasaki KX65 (2010) - page 93

    ENGINE REMOV AL/INST ALLA TION 6-1 6 Engine Removal/Installation T able of Contents Exploded View ................................................................................................................... ..... 6-2 Engine Removal/Installation .................................................................................................. ...

  • Kawasaki KX65 (2010) - page 94

    6-2 ENGINE REMOV AL/INST ALLA TION Exploded View 1. Frame 2. Pivot Shaft 3. Swingarm T1: 25 N·m (2.5 kgf·m, 18 ft·lb) 29 N·m (3.0 kgf·m, 21 ft·lb): KX65-A3 ∼ T2: 69 N·m (7.0 kgf·m, 51 ft·lb) G: Apply grease. L: Apply a non-permanent locking agent. ...

  • Kawasaki KX65 (2010) - page 95

    ENGINE REMOV AL/INST ALLA TION 6-3 Engine Removal/Installation Engine Removal • Drain the engine oil (see Engine Bottom End/T ransmis- sion chapter). • Drain the coolant (see Cooling System chapter). • Remove: Radiator Shrouds Side Covers Seat Fuel T ank W ater Hoses Radiators Expansion Chamber Spark Plug Carburetor (with Cables and Hoses) Cl ...

  • Kawasaki KX65 (2010) - page 96

    6-4 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation Engine Installation • Install the engine on the frame. • Before tightening the engine mounting nuts, measure the left and right clearance [A] between the bosses [B] of crankcase and frame brackets [C] with thickness gauge. Clearance: Under 0.3 mm If the clearances are over the speci ...

  • Kawasaki KX65 (2010) - page 97

    ENGINE BOTTOM END/TRANSMISSION 7-1 7 Engine Bottom End/T ransmission T able of Contents Exploded View ................................................................................................................... ..... 7-2 Specifications ...................................................................................................... .... ...

  • Kawasaki KX65 (2010) - page 98

    7-2 ENGINE BOTTOM END/TRANSMISSION Exploded View ...

  • Kawasaki KX65 (2010) - page 99

    ENGINE BOTTOM END/TRANSMISSION 7-3 Exploded View 1. Crankshaft Assembly 2. Magneto Stator 3. Magneto Flywheel 4. Left Crankcase 5. Right Crankcase 6. Drive Shaft 7. Output Shaft 8. Engine Sprocket 9. Shift Rod 10. Shift Fork 1 1. Operating Plate 12. Shift Drum 13. Shift Shaft 14. Shift Pedal 15. KX65-A1 ∼ A5 16. KX65-A1 ∼ A6 T1: 20 N·m (2.0 kg ...

  • Kawasaki KX65 (2010) - page 100

    7-4 ENGINE BOTTOM END/TRANSMISSION Specifications Item Standard Service Limit T ransmission Oil: Engine Oil: Grade API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 ––– Vis c o si t y SAE10W-40 ––– Capacity 0.5 L ––– Crankshaft, Connecting Rod Connecting Rod Bend Not more than 0.05 mm/100 mm 0.2 mm/100 mm Connecting Rod T wist Not ...

  • Kawasaki KX65 (2010) - page 101

    ENGINE BOTTOM END/TRANSMISSION 7-5 T ran smission Oil In order for the transmission and clutch to function prop- erly , always maintain the trans mission oil at the proper level and change the oil periodically . WA R N I N G V ehicle operation with insufficient, deteriorated, or contaminated transmission oil will cause acceler- ated wear and may re ...

  • Kawasaki KX65 (2010) - page 102

    7-6 ENGINE BOTTOM END/TRANSMISSION T ran smission 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. T orque - Engine Oi l Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb) • ...

  • Kawasaki KX65 (2010) - page 103

    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 T op End Chapter) Cylinder (see Engine T op End Chapter) ...

  • Kawasaki KX65 (2010) - page 104

    7-8 ENGINE BOTTOM END/TRANSMISSION Crankcase • Pull out the shift rods [A]. • Disengage the shift fork guide pins from the shift drum grooves. • T a k eo f ft h es h i f td r u m[ B ] • Remove the shift forks [C] from the transmission gears. • T ake out the drive shaft [D] and output shaft [E] together with their gear meshed. • Remove t ...

  • Kawasaki KX65 (2010) - page 105

    ENGINE BOTTOM END/TRANSMISSION 7-9 Crankcase • T urn the crankshaft [A] to BDC [B], and install the crank- shaft jig [C] between the flywheels opposite the connect- ing rod big end to protect flywheel alignment as shown. Install the suitable shaft [D] to the rear end of the crank- shaft jig. ○ If the crankshaft has been removed from the crankca ...

  • Kawasaki KX65 (2010) - page 106

    7-10 ENGINE BOTT OM END/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Removal • Split the crankcase (see Crankcase Splitting). • Remove the transmission shafts (see T ransmission Shaft Removal). • Using a press, remove the crankshaft from the right crankcase. ○ If the bearings stay on the crankshaft when splitting the crankcase or remo ...

  • Kawasaki KX65 (2010) - page 107

    ENGINE BOTTOM END/TRANSMISSI ON 7-1 1 Crankshaft, C onnecting 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. The dif ference bet ...

  • Kawasaki KX65 (2010) - page 108

    7-12 ENGINE BOTT OM END/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Alignment Inspection • In the case of horizontal misalignment, which is the most common, strike the projecting rim of the flywheel with a plastic, soft lead, or brass hammer as indicated in the figure. • Recheck the runout with a dial gauge, repeat ing the process until ...

  • Kawasaki KX65 (2010) - page 109

    ENGINE BOTTOM END/TRANSMISSION 7-13 T ran smission Shaft Removal • Split the crankcase (see Crankcase Splitting). • Pull off the shift rods [A], a nd 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. • T ake out the drive shaft [D] and out ...

  • Kawasaki KX65 (2010) - page 110

    7-14 ENGINE BOTT OM END/TRANSMISSION T ran smission • 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. [A] 2nd Gear (34T ; dog recesses face rig ...

  • Kawasaki KX65 (2010) - page 111

    ENGINE BOTTOM END/TRANSMISSION 7-15 T ran smission • Install the shift drum. • Fit the shift fork guide pins into the corre sponding shift drum grooves. • Apply a little transmission oil to the shift rods, and slide them into the shift forks. • Holding the shift drum with the suitable tool and tighten the shift drum operating plate bolt. ? ...

  • Kawasaki KX65 (2010) - page 112

    7-16 ENGINE BOTT OM END/TRANSMISSION T ran smission Gear Damage Inspection • Visually inspect the gear teeth on the transmission gears. Repair lightly damaged gear teeth w ith an oilstone. The gear must be replaced if the teet h are badly damaged. When gear is repaired or replaced, the driving gear should also be inspected and repaired or replace ...

  • Kawasaki KX65 (2010) - page 113

    WHEELS/TIRES 8-1 8 Wheels/T ires T able of Contents Exploded View ................................................................................................................... ..... 8-2 Specifications ...................................................................................................... ........... ........ 8-3 Wheels (Rims) . ...

  • Kawasaki KX65 (2010) - page 114

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

  • Kawasaki KX65 (2010) - page 115

    WHEELS/TIRES 8-3 Specifications Item Standard Service Limit Wheels (Rims): Rim Size: Front 14 × 1.40 Rear 12 × 1.60 Rim Runout: Axial 1.0 mm or less 2m m Radial 1.0 mm or less 2m m Axle Runout/100 mm 0.1 mm 0.2 mm Tires Air Pressure Front and Rear 9 8k P a( 1 . 0k g f / c m ² ,1 4p s i ) ––– Tir e s Standard T ire: Front: Size 60/100-14 30 ...

  • Kawasaki KX65 (2010) - page 116

    8-4 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Using the jack [A] under the frame, and stabilize the mo- torcycle. Special T ool - Jack: 57001-1238 • Place a stand under the engine to raise the front wheel the ground. • Remove the cotter pin [A] • Unscrew the axle nut [B]. • Remove the axle [A], and pull out the wheel. T ake off the ...

  • Kawasaki KX65 (2010) - page 117

    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. ○ It should be within 30 degree. ○ Loosen once and tighten again when the slot goes past the nearest hole. • Bend ...

  • Kawasaki KX65 (2010) - page 118

    8-6 WHEELS/TIRES Wheels (Rims) • Remove the cotter pin [A]. • Remove the axle nut [B]. • P u l lo u tt h ea x l e[ C ] . • Move the rear wheel back with the rear caliper installed. • T ake off the collar and cap from the each side of the rear hub. NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp ...

  • Kawasaki KX65 (2010) - page 119

    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. ○ It should be within 30 degree. ○ Loosen once and tighten again when the slot goes past the nearest hole. • Bend ...

  • Kawasaki KX65 (2010) - page 120

    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. Replace them if they are damaged. If the problem is not due to the bearings, correct the rim warp ...

  • Kawasaki KX65 (2010) - page 121

    WHEELS/TIRES 8-9 Tir e s 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 and rider preference, but do not stray too far from the recom- mended pressure. T rack Condition T ire Pressure When the track is wet, mud dy , ...

  • Kawasaki KX65 (2010) - page 122

    8-10 WHEELS/TIRES Tir e s Tir e Re m o v al 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). • T o maintain wheel balance, mark [A] t he valve stem posi- tion on ...

  • Kawasaki KX65 (2010) - page 123

    WHEELS/TIRES 8-1 1 Tir e s 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 ...

  • Kawasaki KX65 (2010) - page 124

    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. • Remove the oil seals and circlip. • Remove the hub bearing by tapping evenl ...

  • Kawasaki KX65 (2010) - page 125

    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 ho le. • Apply high temperature grease to the oil seal lips. Special T ool - Bearing Driver set: 57001-1 129 [C] Inside Circlip Pli ers: 57001-143 Bearing Inspection NOTE ○ ...

  • Kawasaki KX65 (2010) - page 126

    ...

  • Kawasaki KX65 (2010) - page 127

    FINAL DRIVE 9-1 9 Final Drive T able of Contents Exploded View ................................................................................................................... ..... 9-2 Specifications ...................................................................................................... ........... ........ 9-3 Drive Chain ...... ...

  • Kawasaki KX65 (2010) - page 128

    9-2 FINAL DRIVE Exploded View 1. Engine Sprocket 2. Output Shaft 3. Swingarm 4. Chain S lipper 5. Chain Guide 6. Locknut 7. Adjusting Bolt 8. Chain Adjuster 9. Drive Chain 10. Rear Sprocket 1 1. Rear Axle 12. KX65-A6, A6F ∼ T1: 26 N·m (2.7 kgf·m, 20 ft·lb) T2: 79 N·m (8.0 kgf·m, 58 ft·lb) G: Apply grease. L: Apply a non-parmanent locking ag ...

  • Kawasaki KX65 (2010) - page 129

    FINAL DRIVE 9-3 Specifications Item Standard Service Limit Drive Chain Chain Slack 44 ∼ 54 mm ––– 45 ∼ 55 mm (KX65-A3 ∼ ) ––– Chain 20-link Length 254.0 ∼ 254.6 mm 259 mm Standard Chain: Make DAIDO ––– Ty p e DID 420MBK1 ––– Length 108 Links ––– 1 10 Links (KX65-A3 ∼ ) ––– Sprocket Engine Sprocket Diame ...

  • Kawasaki KX65 (2010) - page 130

    9-4 FINAL DRIVE Drive Chain Drive Chain Slack Inspection • Support the motorcycle on its stand. • Check the wheel alignment (see Wheel Alignment Inspec- tion), and adjust it if necessary (see Wheel Alignment Ad- justment). NOTE ○ Clean the drive chain if it is dirty , and lubricate it if it appears dry . • Rotate the rear wheel to find the ...

  • Kawasaki KX65 (2010) - page 131

    FINAL DRIVE 9-5 Drive Chain • Bend the cotter pin [A] over the nut [B]. • Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary . WA R N I N G A loose axle nut can lead to an ac cident resulting in serious injury or death. Tighten the axle nut to the proper torque and install a new cotter pin. NOTE ...

  • Kawasaki KX65 (2010) - page 132

    9-6 FINAL DRIVE Drive Chain • Stretch the chain taut by hanging a 98 N (10 kg, 20 lb) weight [A] on the chain. • Measure the length of 20 links [B] on the straight part [C] of the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the chain may wear unevenly , take measurements at several places. Chain 20-link Len ...

  • Kawasaki KX65 (2010) - page 133

    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]. • Adjust the drive chain slack (see Drive ...

  • Kawasaki KX65 (2010) - page 134

    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 T ool - Outside Circlip Pliers: 57001-144 Engine Sprocket Installation • Replace the circlip with a new one. • Install the circlip so that the tooth is al ...

  • Kawasaki KX65 (2010) - page 135

    FINAL DRIVE 9-9 Sprockets Rear Sprocket Warp Inspection • Using the jack, raise the rear wheel off the ground. Special T ool - Jack: 57001-1238 • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference between the highest and lowest dial gauge ...

  • Kawasaki KX65 (2010) - page 136

    ...

  • Kawasaki KX65 (2010) - page 137

    BRAKES 10-1 10 Brakes T able of Contents Exploded View ................................................................................................................... ..... 10-2 Specifications ...................................................................................................... ........... ........ 10-4 Brake Lever , Brake Peda ...

  • Kawasaki KX65 (2010) - page 138

    10-2 BRAKES Exploded View 1. Front Brake Reservoir 2. Brake Lever 3. Brake Hose 4. Clamps 5. Front Caliper 6. Brake Pad 7. Piston 8. Front Disc 9. KX65A9F ∼ T1: 25 N·m (2.5 kgf·m, 18 ft·lb) T2: 8.8 N·m (0.90 kgf·m, 78 in ·lb) T3: 7.8 N·m (0.80 kgf·m, 69 in ·lb) T4: 18 N·m (1.8 kgf·m, 13 ft·lb) T5: 9.8 N·m (1.0 kgf·m, 87 in·lb) T6: ...

  • Kawasaki KX65 (2010) - page 139

    BRAKES 10-3 Exploded View 1. Rear Brake Reservoir 2. Rear Master Cylinder 3. Brake Hose 4. Brake Pedal 5. Rear Caliper Cover 6. Rear Caliper 7. Piston 8. Brake Pad 9. Rear Disc T1: 25 N·m (2.5 kgf·m, 18 ft·lb) T2: 9.8 N·m (1.0 kgf·m, 87 in·lb) T3: 7.8 N·m (0.80 kgf·m, 69 i n·lb) T4: 18 N·m (1.8 kgf·m, 13 ft·lb) G: Apply high temp eratur ...

  • Kawasaki KX65 (2010) - page 140

    10-4 BRAKES Specifications Item Standard Service Limit Brake Adjustment Lever Play Adjustable (to suit rider) ––– Brake Fluid Recommended Disc Brake Fluid: ––– Ty p e DOT3 or DOT4 ––– Brake Pads Lining Thickness: Front 4.5 mm 0.7 mm Rear 4.5 mm 0.7 mm Brake Disc Thickness: Front 2.80 ∼ 3.20 mm 2.5 mm Rear 2.80 ∼ 3.20 mm 2.5 mm ...

  • Kawasaki KX65 (2010) - page 141

    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. WA R N I N G An improperly adjusted brake could drag and c ...

  • Kawasaki KX65 (2010) - page 142

    10-6 BRAKES Brake Lever , Brake P edal • 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. • Apply high temperature grease to the shaft portion of the brake pedal, and install the pedal wi ...

  • Kawasaki KX65 (2010) - page 143

    BRAKES 10-7 Brake Fluid WA R N I N G When working with the disc brake, observe the pre- cautions listed below . 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling ...

  • Kawasaki KX65 (2010) - page 144

    10-8 BRAKES Brake Fluid Fluid Level Inspection In accordance with the Periodic Maintenance Chart, in- spect the brake fluid level in the front and rear brake fluid reservoirs. • Check the brake fluid level in the front brake reservoir [A]. NOTE ○ Hold the reservoir horizontal when checking brake fluid level. ○ The front reservoir must be kept ...

  • Kawasaki KX65 (2010) - 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. • Remove the rubber cap [A] on the bleed valve [B]. • Attach a clear plastic hose to the bleed valve on the caliper ...

  • Kawasaki KX65 (2010) - page 146

    10-10 BRAKES Brake Fluid Bleeding the Brake Line The brake fluid has a very low co mpression 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 ...

  • Kawasaki KX65 (2010) - page 147

    BRAKES 10-1 1 Brake Fluid • Remove the clear plastic hose. • T ighten the bleed valves, and install the rubber cap. T o rque - Caliper Bleed V alve: 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. WA R N I N G After servicing ...

  • Kawasaki KX65 (2010) - page 148

    10-12 BRAKES Caliper Caliper Removal Front Brake • Loosen the banjo bolt [A] so as not to spill bra ke fluid. • Remove the caliper mounting bolts [B]. • Remove the banjo bolt and take off the brake hose from the caliper [C]. • If the caliper is to be disassembled after removal and if compressed air is not available, remove the piston using ...

  • Kawasaki KX65 (2010) - page 149

    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). ○ Cover the caliper opening with a clean, heavy cloth [A]. ○ Remove the piston ...

  • Kawasaki KX65 (2010) - page 150

    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). • Install the pads (see Pads Installation). ...

  • Kawasaki KX65 (2010) - page 151

    BRAKES 10-15 Caliper Brake Pad Removal • Loosen the pad bolts [A]. • Remove the caliper [B]. • Remove the pad bolts. • T a k eo u tt h ep i s t o ns i d ep a d . • 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 by hand as far as they ...

  • Kawasaki KX65 (2010) - page 152

    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). • When removing the brake hose, ...

  • Kawasaki KX65 (2010) - page 153

    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. • Unscrew the brake hose banjo bolt [D] (see Brake Hose Removal/Installation ...

  • Kawasaki KX65 (2010) - page 154

    10-18 BRAKES Master Cylinder Rear Master Cylinder Dis assembly • Remove the rear master cylinder . • Slide the dust cover [A] on the push rod [B] out of place, and remove the retainer [C]. Special T ool - Inside Circlip Pliers: 57001-143 • Pull out the push rod with the piston stop [D]. • T ake off the piston [E], primary cup [G], and retur ...

  • Kawasaki KX65 (2010) - page 155

    BRAKES 10-19 Master Cylinder Master Cylinder Inspection (V isual 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]. If a master cylinder or piston shows any damage, replace them. • Inspect the p ...

  • Kawasaki KX65 (2010) - page 156

    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 : Front 2.80 ∼ 3.20 mm Rear 2.80 ∼ 3.20 mm Service Li mit ...

  • Kawasaki KX65 (2010) - page 157

    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. • When removing the brake hose, temporaril ...

  • Kawasaki KX65 (2010) - page 158

    ...

  • Kawasaki KX65 (2010) - page 159

    SUSPENSION 1 1-1 11 Suspension T able of Contents Exploded View ................................................................................................................... ..... 1 1-2 Specifications ...................................................................................................... ........... ........ 1 1-6 Front Fork .. ...

  • Kawasaki KX65 (2010) - page 160

    1 1-2 SUSPENSION Exploded View ...

  • Kawasaki KX65 (2010) - page 161

    SUSPENSION 1 1-3 Exploded View 1. T op Plug 2. O-ring 3. Fork Spring 4. Piston Cylinder Unit 5. Inner T ube 6. Guide Bushes 7. Dust Seal 8. Retaining Ring 9. Oil Seal 10. W asher 1 1. Outer Tube 12. Gasket 13. Allen Bolt 14. Steering Stem Head 15. Steering Stem 16. Spring Seat 17. KX65-A3 ∼ T1: 22 N·m (2.2 kgf·m, 16 ft·lb) T2: 20 N·m (2.0 kgf ...

  • Kawasaki KX65 (2010) - page 162

    1 1-4 SUSPENSION Exploded View ...

  • Kawasaki KX65 (2010) - page 163

    SUSPENSION 1 1-5 Exploded View 1. Pivot Shaft 2. Swingarm 3. Rocker Arm 4. T ie-rod 5. Rear Shock Absorber 6. Rear Shock Absorber (KX65-A3 ∼ ) T1: 69 N·m (7.0 kgf·m, 51 ft·lb) T2: 83 N·m (8.5 kgf·m, 61 ft·lb) T3: 59 N·m (6.0 kgf·m, 43 ft·lb) T4: 34 N·m (3.5 kgf·m, 25 ft·lb) T5: 39 N·m (4.0 kgf·m, 29 ft·lb) G: Apply grease. L: Apply ...

  • Kawasaki KX65 (2010) - page 164

    1 1-6 SUSPENSION Specifications Item Standard Service Limit Front Fork Oil Vi scosity SHOW A SS-8 or equivalent ––– Oil Capacity (Completely Dry) 238 ±2.5 mL (KX65-A1) ––– 240 ±2.5 mL (KX65-A2) ––– 252 ±2.5 mL (KX65-A3 ∼ ) ––– Oil Level (Fully Compressed, Spring Removed) 124 ±2 mm (KX65-A1) (from top of inner tube) 98 ...

  • Kawasaki KX65 (2010) - page 165

    SUSPENSION 1 1-7 Front Fork The front fork should always be adjusted for the rider ’s weight and track conditions by using one or more of the following methods. ○ Oil level adjustment - The ef fects of higher or lower fork oil level are only felt during the final 100 mm of fork travel. A higher oil level (more oil ) will make the fork repulsion ...

  • Kawasaki KX65 (2010) - page 166

    1 1-8 SUSPENSION Front Fork KX65-A3 ∼ • Remove: Number Plate Handlebar Assembly Front Fork T op Plug [A] Fork Spring [B] Fork Spring Seat [C] • Slowly compress the front fork fully by pushing up the outer tubes [A] using a jack or other suitable means under the front wheel. • Place a stand or other suitable support [B] under the front wheel ...

  • Kawasaki KX65 (2010) - page 167

    SUSPENSION 1 1-9 Front Fork • Check both top plug O-ring [A] for damage and replace them if necessary . • Install the fork top plug. • Install the fork top plug and fork spring seat (KX65-A3 ∼ ). • T ighten the fork top plug. T o rque - Fron t Fork T op Pl ug: 22 N ·m (2.2 kgf·m, 16 ft ·lb) • Assemble the other fork tube in the same ...

  • Kawasaki KX65 (2010) - page 168

    1 1-10 SUSPENSION Front Fork • Adjust the oil level. ○ With the fork fully compressed, put the oil level gauge [A] and the stopper [B], and inspect the distance from t he top of the inner tube to the oil. Special T ool - Fork Oil Level Gauge: 57001-1290 Oil Level (full y compressed, without spring) Standard: 1 24 ±2 mm (KX65-A1 ) 126 ±2 mm (K ...

  • Kawasaki KX65 (2010) - page 169

    SUSPENSION 1 1-1 1 Front Fork Front Fork Installation • If the fork leg was disassembled, check the fork oil level. • Install the fork so that the top end [A] of the inner tube is 10 mm up [B] with the upper surface [C] of the steering stem head. • Install the fork so that the top end [A] of the inner tube is 20 mm up [B] with the upper surfa ...

  • Kawasaki KX65 (2010) - page 170

    1 1-12 SUSPENSION Front Fork • Remove the cylinder unit [A] and spring [B] from the fork. • Remove the dust seal [A] and retaining ring [B]. • Use the fork outer tube weight [A] to separate the inner tube from the outer tube. Special T ool - Fork O uter T ube Weight : 57001-1218 ○ Holding the inner tube by hand in a vertical position, pull ...

  • Kawasaki KX65 (2010) - page 171

    SUSPENSION 1 1-13 Front Fork Front Fork Assembly (each fork) • Assembly is the reverse of disassembly . • Replace the following parts removed with a new one. Guide Bushes Oil Seal Bottom Allen Bolt Gasket • Inspect the following and replace them with new ones if damaged. Inner T ube (see Inner Tube Inspection) T o pP l u gO - r i n g • Inse ...

  • Kawasaki KX65 (2010) - page 172

    1 1-14 SUSPENSION Front Fork Inner Tube Inspection • Visually inspect th e inner tube [A], repair any damage. • Nick or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil ...

  • Kawasaki KX65 (2010) - page 173

    SUSPENSION 1 1-15 Rear Suspension (Uni-T rak) Rear Shock Absorber The rear suspension system of this motorcycle is Uni-trak. It consists of a rear shock absorber , swingarm, tie-rod and rocker arm. T o suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one. KX65 ...

  • Kawasaki KX65 (2010) - page 174

    1 1-16 SUSPENSION Rear Suspension (Uni-T rak) • Using the hook wrench [A], turn the adjusting nut [B] as required. Turning the adjusting nut downward marks the spring action harder and upward softer . Special T ool - Hook Wrench: 57001-1 101 Spring Preload Adjust ment (Adjusting nut posit ion [A] from the center of the mounting hole) Standard: 88 ...

  • Kawasaki KX65 (2010) - page 175

    SUSPENSION 1 1-17 Rear Suspension (Uni-T rak) • Remove the rear shock absorber upper mounting bolt [A], and pull out the rear shock absorber [B]. Rear Shock Absorber Installation • Pack the rocker arm needle bearings with grease. • T ighten the following: T orque - Rear Shock Absorber Mounting Bol t (Upper): 39 N·m (4.0 kg f·m, 29 ft· lb) ...

  • Kawasaki KX65 (2010) - page 176

    1 1-18 SUSPENSION Rear Suspension (Uni-T rak) • Remove the rear shock absorber from the vise. • Remove the stopper ring [A]. • Remove the spring seat [B] from the shock absorber and lift off the spring [C]. • Install the spring guide. • Adjust the spring preload (see Spring Preload Adjust- ment). • Install the rear shock absorber . • ...

  • Kawasaki KX65 (2010) - page 177

    SUSPENSION 1 1-19 Swingarm Swingarm Removal • Place the jack under the frame so that the rear wheel is off the ground. Special T ool - Jack: 57001-1238 • Remove the rear wheel (see Wheels/T ires chapter). • Remove the brake pedal [A]. • Remove the tie-rod rear mounting bolt [B]. NOTICE When pulling out the mounting bolts, lift the rear whee ...

  • Kawasaki KX65 (2010) - page 178

    1 1-20 SUSPENSION Swingarm Swingarm Bearing Installation • Replace the needle bearings, dust seals and oil seals with new ones. • Apply plenty of grease to the dust seals, oil seals and needle bearings. NOTE ○ Install the needle bearings so that the manufacturer ’s marks face out. Special T ool - Bearing Driver Set: 57001-1 129 • Install ...

  • Kawasaki KX65 (2010) - page 179

    SUSPENSION 1 1-21 Tie-rod, Rocker Arm Tie-rod Removal • Using the jack under the frame, raise the rear wheel off the ground. Special T ool - Jack: 57001-1238 • Remove the tie-rod front mounting bolt [A]. NOTICE When pulling out the mounting bolts, lift the rear wheel slightly . Forcing or tapping on a bolt could damage the bolt, sleeve, and bea ...

  • Kawasaki KX65 (2010) - page 180

    1 1-22 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. • T ighten the following: T orque - Rocker Arm Pivot Nut: 83 ...

  • Kawasaki KX65 (2010) - page 181

    SUSPENSION 1 1-23 Uni-T rak Maintenance Check the uni-trak component parts for wear periodically , or whenever excessive play is suspected. • Using the jack under the frame, raise the rear wheel off the ground. Special T ool - Jack: 57001-1238 • Push and pull on the swingarm [A], up and down, to check for wear . A small amount of play on the sw ...

  • Kawasaki KX65 (2010) - page 182

    ...

  • Kawasaki KX65 (2010) - page 183

    STEERING 12-1 12 Steering T able of Contents Exploded View ................................................................................................................... ..... 12-2 Specifications ...................................................................................................... ........... ........ 12-3 Steering ........... ...

  • Kawasaki KX65 (2010) - page 184

    12-2 STEERING Exploded View 1. Handlebar Clamp 2. Handlebar 3. Steering Stem Head Nut 4. Steering Stem Head Bracket 5. Steering Stem Nut 6. T apered Roller Bearing 7. Head Pipe 8. T apered Roller Bearing 9. Steering Stem T1: 44 N·m (4.5 kgf·m, 33 ft·lb) T2: 20 N·m (2.0 kgf·m, 15 ft·lb) T3: 2.9 N·m (0.30 kgf·m, 26 in ·lb) T4: 25 N·m (2.5 k ...

  • Kawasaki KX65 (2010) - page 185

    STEERING 12-3 Specifications Special T ools - Steering Stem Bearing Dr iver: 57001-137 Head Pipe Outer Rac e Press Shaft: 57001-1075 Steering Stem Beari ng Driver Adapter: 57001-1092 Steering Stem Nut Wr ench: 57001-1 100 Head Pipe Outer Race Driver: 57001-1 106 Head Pipe Outer Race Remover: 57001-1 107 Jack: 57001-1 238 ...

  • Kawasaki KX65 (2010) - page 186

    12-4 STEERING Steering Steering Inspection • Using the jack, raise the front wheel off the ground. Special T ool - Jack: 57001-1238 • With the front wheel pointing straight ahead, alternately nudge each end of the handlebar . The front wheel should swing fully left and right from the force of gravity until the fork hits the stop. If the steerin ...

  • Kawasaki KX65 (2010) - page 187

    STEERING 12-5 Steering Steering Ste m, Stem Bear ing Remova l • Remove: Front Wheel (see Wheels/T ires 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) • Remove ...

  • Kawasaki KX65 (2010) - page 188

    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 T ools - Head Pipe Oute r Race Press Shaft : 57001 -1075 Head Pipe Outer Race Driver: 57001-1 106 • Replace ...

  • Kawasaki KX65 (2010) - page 189

    STEERING 12-7 Steering T orque - Steering Stem Head Nut: 44 N·m (4.5 kgf·m, 33 ft·lb) Front Fork Clamp Bolt: Upper: 20 N·m (2.0 kgf·m, 15 ft· lb) Lower: 29 N·m (3.0 kgf ·m, 22 ft·lb) • Install the parts removed (see the appropriate chapter). WA R N I N G Do not impede the handlebar turning by routing the cables, wires and hoses improperl ...

  • Kawasaki KX65 (2010) - page 190

    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. • Visually check th ...

  • Kawasaki KX65 (2010) - page 191

    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]. • Install the front master cylinder (see Front Master Cylinder Instal ...

  • Kawasaki KX65 (2010) - page 192

    ...

  • Kawasaki KX65 (2010) - page 193

    ELECTRICAL SYSTEM 13-1 13 Electrical System T able of Contents Wiring Diagram .................................................................................................................. ..... 13-2 Exploded View ................................................................................................................... ..... 13-3 Speci ...

  • Kawasaki KX65 (2010) - page 194

    13-2 ELECTRICAL SYSTEM Wiring Diagram KX65A6F ∼ ...

  • Kawasaki KX65 (2010) - page 195

    ELECTRICAL SYSTEM 13-3 Exploded V iew 1. Magneto Cover 2. Magneto Flywheel 3. Stator 4. CDI Unit 5. Ignition Coil 6. Spark Plug Cap 7. Spark Plug 8. Engine Stop Button 9. KX65-A1 ∼ A6 T1: 29 N·m (3.0 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) SS: Apply silico ...

  • Kawasaki KX65 (2010) - page 196

    13-4 ELECTRICAL SYSTEM Specifications Item Standard Magneto Stator coil resistance in the text Ignition System Ignition T iming: 20.5° BTDC @6 000 r/min (rpm) 20.5° BTDC @7 100 r/min (rpm) (KX65A6F ∼ ) Ignition Coil: 3 Needle Arcing Distance 7m mo rm o r e Primary Winding Resistance 0.31 Ω ±15% (at 20°C) Secondary Winding Resistance 3.1 k ? ...

  • Kawasaki KX65 (2010) - page 197

    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. ○ T roubles may invo ...

  • Kawasaki KX65 (2010) - page 198

    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 . If it is damaged, replace it ...

  • Kawasaki KX65 (2010) - page 199

    ELECTRICAL SYSTEM 13-7 Ignition T iming 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]. • T i ght ...

  • Kawasaki KX65 (2010) - page 200

    13-8 ELECTRICAL SYSTEM Flywheel Magneto Flywheel Magneto Remo val • Remove the magneto cover . • Hold the flywheel steady , with t he flywheel & pulley holder [A], and remove the flywheel nut [B]. Special T ool - Flywheel & Pulley Holder: 57001-1343 • Screw the flywheel puller [A] into the flywheel by turning it counterclockwise (left ...

  • Kawasaki KX65 (2010) - page 201

    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 woodruf f key [A] securely in the slot in the crank- shaft before installing the stator plate. • Holding the flywheel steady , ...

  • Kawasaki KX65 (2010) - page 202

    13-10 ELECTRICAL SYSTEM Flywheel Magneto • T o 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. T able 2 Stator Coil Resistance Connections T ester Range Te s t e r ( + ) Te s t e r ( – ) t o Reading ×1 Ω Bla ck/Re d Lead Bla ...

  • Kawasaki KX65 (2010) - page 203

    ELECTRICAL SYSTEM 13-1 1 Ignition System Safety Instructions WA R N I N G The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Crankshaft Sensor Installation ( KX65A6F ∼ ) • Install the crankshaft sen ...

  • Kawasaki KX65 (2010) - page 204

    13-12 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak V oltage 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 lead of the adapter to White/Green lea ...

  • Kawasaki KX65 (2010) - page 205

    ELECTRICAL SYSTEM 13-13 Ignition System WA R N I N G T o avoid extremely high voltage shocks, do not touch the coil or lead. If the distance reading is less than the specified value, the ignition coil or spark plug cap is defective. 3N e e d l eA r c i n gD i s t a n c e Standard : 7m mo rm o r e • T o determine which part is defective, measure t ...

  • Kawasaki KX65 (2010) - page 206

    13-14 ELECTRICAL SYSTEM Ignition System Spark Plug Cleaning and Inspection • Remove the spark plug, and visually inspect it. • Clean the spark plug, prefer ably in a sandblasting device, and then clean off any abra sive particles. The plug may also be cleaned using a high flash-point solvent and a wire brush or other suitable tool. If the spark ...

  • Kawasaki KX65 (2010) - page 207

    ELECTRICAL SYSTEM 13-15 Ignition System Ignition Coil Primary Peak V oltage Check • Remove: Shrouds Side Covers Seat Fuel T ank • Disconnect the spark plug cap from the spark plug [A]. • Connect the new spark plug [B] to the spark plug cap, then ground it to the engine. NOTE ○ Measure the voltage with each lead connected cor - rectly . The ...

  • Kawasaki KX65 (2010) - page 208

    13-16 ELECTRICAL SYSTEM Ignition System ...

  • Kawasaki KX65 (2010) - page 209

    ELECTRICAL SYSTEM 13-17 Ignition System Exciter (Stator) Coil Peak V oltage Check • Disconnect the connector of the harness from the CDI Unit. • T o check the peak voltage, do the following procedures. NOTE ○ Measure the voltage with each lead connected cor - rectly . The correct value may not be obtained if disconnected. ○ Maintain the cor ...

  • Kawasaki KX65 (2010) - page 210

    ...

  • Kawasaki KX65 (2010) - page 211

    APPENDIX 14-1 14 Appendix T able of Contents T roubleshooting Guide ........................................................................................ ................... 14-2 General Lubrication ............................................................................................................. ... 14-6 Lubrication (Periodic M ainte ...

  • Kawasaki KX65 (2010) - page 212

    14-2 APPENDIX T roubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some o f the more common difficulties. Engine Doesn’t Start, Starting Difficulty: Engine won’t turn over: Cylinder , piston seizure Crankshaft se ...

  • Kawasaki KX65 (2010) - page 213

    APPENDIX 14-3 T roubleshooting Guide Flywheel magneto damaged Ignition coil lead or CDI Unit lead not in good contact Fuel/air mixture incorrect: Main jet clogged or wrong size Jet needle or needle jet worn Jet needle clip in wrong position Float level too high or too low Air jet or air passage clogged Air cleaner clogged, poorly sealed, or miss- i ...

  • Kawasaki KX65 (2010) - page 214

    14-4 APPENDIX T roubleshooting Guide Jumps out of gear: Shift fork worn Gear groove worn Gear dogs and/or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro- ken Shift fork guide pin worn Drive shaft, output shaft, and/or gear splines worn Overshifts: Gear positioning lever spring weak or bro- ken Shift mechanism arm sp ...

  • Kawasaki KX65 (2010) - page 215

    APPENDIX 14-5 T roubleshooting Guide Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Steering stem bent Front fork leg bent Right/left front fork oil level uneven Shock absorption unsatisfactory: (T oo hard) Front fork oil excessive Front fork oil viscosity too high Front fork leg bent T ire ai ...

  • Kawasaki KX65 (2010) - page 216

    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 ...

  • Kawasaki KX65 (2010) - page 217

    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). If there are loose fasteners, retorque th ...

  • Kawasaki KX65 (2010) - page 218

    14-8 APPENDIX Unit Conversion T able Prefixes for Units: Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units of Mass: kg × 2.205 = lb g × 0.03527 = oz Units of V olume: L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L × 1.057 = qt (US) L × 0.8799 = qt (imp) L× 2 . 1 1 3 = pint ( ...

  • Kawasaki KX65 (2010) - page 219

    MODEL APPLICA TION Y ear Model Beginning Frame No. 2000 KX65-A1 JKBKEAC □ Y A000001 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 JKBKX065AAA036001 2005 KX65-A6 JKBKXE ...

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