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Kawasaki KX65 - Service Manual

Other manuals for KX65 -: Brochure, Owner's Manual

Summary of KX65 -

  • Page 1

    Kx65 motorcycle service manual.

  • Page 3: Quick Reference Guide

    This quick reference guide will assist you in locating a desired topic or pro- cedure. •bend the pages 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 th...

  • Page 5: Kx65

    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 assurance division...

  • Page 6

    List of abbreviations a ampere(s) lb pound(s) abdc after bottom dead center m meter(s) ac alternating current min minute(s) atdc 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...

  • Page 7: Foreword

    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 prope...

  • Page 9: General Information

    General information 1-1 1 general information table of contents before servicing ..................................................................................................................... 1-2 model identification................................................................................

  • Page 10

    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...

  • Page 11

    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 ...

  • Page 12

    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...

  • Page 13

    General information 1-5 model identification kx65-a1 left side view kx65-a1 right side view.

  • Page 14

    1-6 general information 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 1 110 mm 1 120 mm road clearance 270 mm (kx...

  • Page 15

    General information 1-7 general specifications items kx65-a1 ∼ a2 kx65-a3 ∼ a6, a6f ∼ abf drive train primary reduction system: type gear ← reduction ratio 3.500 (77/22) ← clutch type wet, multi disc ← transmission: type 6-speed, constant mesh, return shift ← gear ratios: 1st 2.846 (37/13) ← 2nd 2.1...

  • Page 16

    1-8 general information general specifications items kx65-a1 ∼ a2 kx65-a3 ∼ a6, a6f ∼ abf brake type: front and rear single disc ← effective disc diameter: front 154.8 mm ← rear 146 mm ← specifications are subject to change without notice, and may not apply to every country. Us: united states model.

  • Page 17

    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...

  • Page 18

    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...

  • Page 19

    General information 1-11 torque and locking agent tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening torque for ...

  • Page 20

    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...

  • Page 21

    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 ...

  • Page 22

    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 pis...

  • Page 23

    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 ...

  • Page 24

    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: 5...

  • Page 25

    General information 1-17 special tools and sealants liquid gasket, tb1211: 56019-120 liquid gasket, tb1105b: 92104-002.

  • Page 26

    1-18 general information cable, wire and hose routing 1. Throttle cable 2. Carburetor 3. Breather hose 4. Air vent 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 figur...

  • Page 27

    General information 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 f...

  • Page 28

    1-20 general information cable, wire and hose routing 1. Clamp 2. Cdi unit (kx65-a1 ∼ a6) 3. Band 4. Clamp the magneto leads at the upper part of the left on the carburetor holder. 5. Magneto leads 6. Shift pedal 7. 19 ±10 mm (shift pedal position) 8. Engine stop button lead 9. Ignition coil 10. Eng...

  • Page 29

    General information 1-21 cable, wire and hose routing 1. Front brake reservoir 2. Banjo bolts 3. Clamp 4. Front brake disk 5. Bleed valves 6. Front brake caliper 7. Rear brake caliper 8. Rear brake disk 9. Rear brake reservoir 10. Rear brake master cylinder 11. Bend the cotter pin end by along the j...

  • Page 30

    1-22 general information cable, wire and hose routing kx65a6f ∼ 1. Throttle cable 2. Clutch cable 3. Band 4. Engine stop button lead 5. Clamp 6. Cdi unit 7. Band 8. Cdi unit ground lead 9. Ignition coil primary lead 10. Ignition coil ground lead 11. Ignition coil 12. Band 13. Clamp the magneto lead ...

  • Page 31: Fuel System

    Fuel system 2-1 2 fuel system table of contents exploded view........................................................................................................................ 2-2 specifications ......................................................................................................

  • Page 32

    2-2 fuel system exploded view 1. Throttle cable 2. Throttle grip 3. Carburetor holder 4. Carburetor cap 5. Spring 6. Retainer 7. Jet needle clip 8. Jet needle 9. Throttle valve 10. Choke knob 11. Idle adjusting screw 12. Spring 13. Air screw 14. Slow jet 15. Float valve needle 16. Main jet 17. Float...

  • Page 33

    Fuel system 2-3 exploded view 1. Fuel tank cap 2. Fuel tank 3. Fuel tap 4. Air cleaner housing 5. Element 6. Frame 7. Holder 8. Air cleaner duct 9. Kx65a6f ∼ t1: 34 n·m (3.5 kgf·m, 25 ft·lb) t2: 8.8 n·m (0.90 kgf·m, 78 in·lb) t3: 3.0 n·m (0.31 kgf·m, 27 in·lb) g: apply grease. O: high-quality foam-a...

  • Page 34

    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...

  • Page 35

    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 wil...

  • Page 36

    2-6 fuel system throttle grip and cable throttle cable installation • install the throttle cable in accordance with the cable, wire and hose routing section in the general informa- tion chapter. • after the installation, adjust each cable properly. Warning operation with incorrectly routed or improp...

  • Page 37

    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 imp...

  • Page 38

    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...

  • Page 39

    Fuel system 2-9 carburetor • drive out the pivot pin [a] and remove the float [b]. • bend the tang [a] on the float arm very slightly to change the float height. Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level. Float height standard: 21.1 ±1 mm...

  • Page 40

    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 ...

  • Page 41

    Fuel system 2-11 carburetor • turn the fuel tap to the on position, and check for fuel leakage from the carburetor. Warning fuel spilled from the carburetor is hazardous. • adjust the following items if necessary: throttle cable (see this chapter) idle speed (see this chapter) fuel inspection warnin...

  • Page 42

    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 scr...

  • Page 43

    Fuel system 2-13 carburetor carburetor cleaning warning gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the carburetor in a well ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any ap...

  • Page 44

    2-14 fuel system carburetor • remove the carburetor. • before disassembling the carburetor, check the fuel level (see fuel level inspection). If the fuel level is incorrect, inspect the rest of the carbu- retor before correcting it. • pull the carburetor cable to check that the throttle valve [a] mo...

  • Page 45

    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 cleaner housing [e]. Air cleaner ho...

  • Page 46

    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...

  • Page 47

    Fuel system 2-17 fuel tank fuel tank removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot l...

  • Page 48

    2-18 fuel system fuel tank fuel tap inspection • remove the fuel tap. • check the fuel tap filter screen [a] for any breaks or dete- rioration. If the fuel tap screen have any breaks or is deteriorated, it may allow dirt to reach the carburetor, causing poor run- ning. Replace the fuel tap. If the f...

  • Page 49

    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], a...

  • Page 50

    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 th...

  • Page 51: Cooling System

    Cooling system 3-1 3 cooling system table of contents exploded view........................................................................................................................ 3-2 specifications ................................................................................................

  • Page 52

    3-2 cooling system exploded view 1. Radiator 2. Radiator cap 3. Water pump cover 4. Drain plug 5. Impeller 6. Oil seal (short) 7. Oil seal (long) 8. Bearing 9. Water pump gear 10. Right engine cover 11. 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...

  • Page 53

    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 ...

  • Page 54

    3-4 cooling system coolant check the coolant level each day before riding the motor- cycle, and replenish coolant if the level is low. Change the coolant in accordance with the periodic maintenance chart (see general information chapter). Warning hot engine coolant can cause serious burns. To avoid ...

  • Page 55

    Cooling system 3-5 coolant coolant draining the coolant should be changed periodically to ensure long engine life. Warning coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it...

  • Page 56

    3-6 cooling system coolant • fill the radiator up to the bottom of the radiator filler neck [b] with coolant [a], and install the cap, turning it clockwise about 1/4 turn. Note ○ pour in the coolant slowly so that it can expel the air from the engine and radiator. The radiator cap must be installed ...

  • Page 57

    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...

  • 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 the system with coolant, bleed any air from the system..

  • Page 59

    Cooling system 3-9 water pump water pump cover removal • drain the coolant (see coolant draining). • loosen the water hose clamps [a], and disconnect the water hoses on the water pump cover [b]. • unscrew the cover bolts [c], and remove the water pump cover. Water pump cover installation • replace t...

  • Page 60

    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 side chapter)...

  • Page 61

    Cooling system 3-11 water pump • press the ball bearing [a] into the hole until the bearing is bottomed against the step [b]. Special tools - bearing driver set: 57001-1129 • apply plenty of high temperature grease to the oil seal lips [d]. • set the oil seal (thick) so that dual lips side face outw...

  • Page 62

    3-12 cooling system radiator radiator removal • drain the coolant (see coolant draining). • remove: left shroud [a] water hose [b] radiator mounting bolts [c] radiator screen [d] breather hose radiator [e] radiator installation • radiator installation is the reverse of removal. • route the water and...

  • 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 radiator cap. If any one of them shows visible damage, replace the cap. • wet the top and bottom valve seals with water or coolant to prevent pressure leaks. • ins...

  • Page 65: Engine Top End

    Engine top end 4-1 4 engine top end table of contents exploded view........................................................................................................................ 4-2 specifications ................................................................................................

  • Page 66

    4-2 engine top end exploded view 1. Spark plug 2. Cylinder head 3. Cylinder 4. Piston ring 5. "1n" mark 6. "2n" mark 7. Piston 8. "in" mark 9. Piston pin 10. Expansion chamber 11. 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·l...

  • Page 67

    Engine top end 4-3 specifications item standard service limit cylinder head cylinder compression (usable range) – – – 755 ∼ 1 177 kpa (7.70 ∼ 12.0 kgf/cm², 109 ∼ 171 psi) cylinder head warp – – – 0.03 mm cylinder, piston cylinder inside diameter (15 mm below from the cylinder top end) 44.500 ∼ 44.51...

  • Page 68

    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 syste...

  • Page 69

    Engine top end 4-5 cylinder head cylinder head installation • replace the head gasket with a new one. • scrape out any carbon and clean the head with a high flash-point solvent. • check for a crust of minerals and rust in the head water jacket, and remove them if necessary. • install a new cylinder ...

  • Page 70

    4-6 engine top end cylinder cylinder removal • drain the coolant (see cooling system chapter). • remove: cylinder head (see this chapter) carburetor (see fuel system chapter) water hose upper end clutch cable lower end muffler holding springs • remove the cylinder nuts [a]. • lift off the cylinder [...

  • Page 71

    Engine top end 4-7 cylinder piston installation • stuff a clean cloth into the crankcase opening around the connecting rod so that no parts will fall into the crankcase. • scrape off any carbon of the piston, then lightly polish the piston with fine emery cloth. • clean carbon and dirt out of the pi...

  • Page 72

    4-8 engine top end cylinder cylinder wear inspection note ○ measure the cylinder inside diameter when the cylinder is cold (room or ambient temperature). • visually inspect the inside of the cylinder for scratches and abnormal wear. If the cylinder is damaged or badly worn, replace it with a new one...

  • Page 73

    Engine top end 4-9 cylinder piston ring, piston ring groove inspection • visually inspect the piston rings and the piston ring grooves. If the rings are worn unevenly or damaged, they must be replaced. If the piston ring grooves are worn unevenly or damaged, the piston must be replaced and fitted wi...

  • Page 74

    4-10 engine top end cylinder piston, piston pin, connecting rod wear inspection • visually inspect the snap ring [a] still fitted in place. If the ring shows weakness or deformation, replace the ring. Also if the pin hole groove shows excessive wear, replace the piston. • measure the diameter of the...

  • Page 75

    Engine top end 4-11 muffler (expansion chamber) muffler removal • remove: right shroud right side cover • remove the muffler mounting bolts [b] and pull the muffler [a] off toward the rear. • remove the springs [a] holding the exhaust pipe holding . • remove the expansion chamber damper mounting bol...

  • Page 76

    4-12 engine top end muffler (expansion chamber) • unscrew the inner pipe mounting bolts [a]. • pull the inner pipe [b] from the muffler body. • pull off the old muffler baffle, and install the new muffler baffle [a] into the muffler body. • apply silicone sealant to the circumference [b] of the inne...

  • Page 77: Engine Right Side

    Engine right side 5-1 5 engine right side table of contents exploded view........................................................................................................................ 5-2 specifications ..........................................................................................

  • Page 78

    5-2 engine right side exploded view.

  • 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 11. Clutch housing 12. Sleeve 13. Primary gear 14. Gear set levers 15. Shift shaft 16. Kicksta...

  • 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 warp not more than 0.15 mm 0.3 mm clutch sprin...

  • 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 adjusted in accor- dance with the periodic maintenance chart. Warning the engine and exhaust system get extremely hot during normal operation and can cause serious bur...

  • 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]. • lin...

  • 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/transmission chapter). • drain the coolant (see coolant draining in the cooling system chapter). • remove: water hose lower ends kick pedal clutch cable lower en...

  • 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]....

  • 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 o...

  • 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...

  • Page 87

    Engine right side 5-11 clutch notice if dry steel plates and friction plates are installed, apply transmission oil to the surfaces of each plate to avoid clutch plate seizure. ○ install the friction plates and steel plates, starting with a friction plate and alternating them, finishing with a fricti...

  • Page 88

    5-12 engine right side clutch spring free length measurement • since the spring [a] becomes shorter as it weakens, check its free length to determine its condition. If any of the springs is shorter than the service limit, it must be replaced. Clutch spring free length standard: 28.1 mm service limit...

  • Page 89

    Engine right side 5-13 external shift mechanism external shift mechanism removal • remove: shift pedal right engine cover clutch housing • remove the engine mounting bolts [a] to pull out the ex- ternal shift mechanism. • pull out the external shift mechanism [a], lifting the engine [b]. • remove th...

  • 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 tools - outside circlip pliers: 57001-144 primary gear installation • put the wate...

  • Page 91

    Engine right side 5-15 primary gear • install the spring washer [a] with the concave side facing to the inward. • temporarily tighten the primary gear nut [b]. • tighten the primary gear nut ○ primary gear nut is left-hand threads. Torque - primary gear nut: 49 n·m (5.0 kgf·m, 36 ft·lb) special tool...

  • 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]. •...

  • Page 93: Engine Removal/installation

    Engine removal/installation 6-1 6 engine removal/installation table of contents exploded view........................................................................................................................ 6-2 engine removal/installation .........................................................

  • Page 94

    6-2 engine removal/installation exploded view 1. Frame 2. Pivot shaft 3. Swingarm t1: 25 n·m (2.5 kgf·m, 18 ft·lb) 29 n·m (3.0 kgf·m, 21 ft·lb): kx65-a3 ∼ t2: 69 n·m (7.0 kgf·m, 51 ft·lb) g: apply grease. L: apply a non-permanent locking agent..

  • Page 95

    Engine removal/installation 6-3 engine removal/installation engine removal • drain the engine oil (see engine bottom end/transmis- sion chapter). • drain the coolant (see cooling system chapter). • remove: radiator shrouds side covers seat fuel tank water hoses radiators expansion chamber spark plug...

  • Page 96

    6-4 engine removal/installation 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 ...

  • Page 97: Table Of Contents

    Engine bottom end/transmission 7-1 7 engine bottom end/transmission table of contents exploded view........................................................................................................................ 7-2 specifications ................................................................

  • Page 98

    7-2 engine bottom end/transmission exploded view.

  • 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 11. Operating plate 12. Shift drum 13. Shift shaft 14. Shift pedal 15. Kx65...

  • Page 100

    7-4 engine bottom end/transmission specifications item standard service limit transmission oil: engine oil: grade api sg, sh, sj, sl or sm with jaso ma, ma1 or ma2 – – – viscosity sae10w-40 – – – capacity 0.5 l – – – crankshaft, connecting rod connecting rod bend not more than 0.05 mm/100 mm 0.2 mm/...

  • Page 101

    Engine bottom end/transmission 7-5 transmission oil in order for the transmission and clutch to function prop- erly, always maintain the transmission oil at the proper level and change the oil periodically. Warning vehicle operation with insufficient, deteriorated, or contaminated transmission oil w...

  • Page 102

    7-6 engine bottom end/transmission transmission oil • check the gasket at the engine oil drain plug for damage. Replace the gasket with a new one if it is damaged. • after the oil has completely drained out, install the engine oil drain plug with the gasket, and tighten it. Torque - engine oil drain...

  • 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 top end chap...

  • 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. • 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] together with the...

  • Page 105

    Engine bottom end/transmission 7-9 crankcase • turn the crankshaft [a] to bdc [b], and install the crank- shaft jig [c] between the flywheels opposite the connect- ing rod big end to protect flywheel alignment as shown. Install the suitable shaft [d] to the rear end of the crank- shaft jig. ○ if the...

  • Page 106

    7-10 engine bottom end/transmission crankshaft, connecting rod crankshaft removal • split the crankcase (see crankcase splitting). • remove the transmission shafts (see transmission shaft removal). • using a press, remove the crankshaft from the right crankcase. ○ if the bearings stay on the cranksh...

  • Page 107

    Engine bottom end/transmission 7-11 crankshaft, connecting rod connecting rod big end radial clearance inspection • set the crankshaft in a flywheel alignment jig or on v blocks, and place a dial gauge against the connecting rod big end. • push the connecting rod first towards the gauge and then in ...

  • Page 108

    7-12 engine bottom end/transmission crankshaft, connecting rod crankshaft alignment inspection • in the case of horizontal misalignment, which is the most common, strike the projecting rim of the flywheel with a plastic, soft lead, or brass hammer as indicated in the figure. • recheck the runout wit...

  • Page 109

    Engine bottom end/transmission 7-13 transmission shaft removal • split the crankcase (see crankcase splitting). • pull off the shift rods [a], and disengage the shift fork guide pins from the shift drum grooves. • remove the shift drum [b] • remove the shift forks [c] from the transmission gears. • ...

  • Page 110

    7-14 engine bottom end/transmission transmission • the output shaft gears can be identified by size; the largest diameter gear is 1st gear, and the smallest is 6th. Be sure that all parts are put back in the correct sequence and facing the proper direction, and that all circlips are properly in plac...

  • Page 111

    Engine bottom end/transmission 7-15 transmission • install the shift drum. • fit the shift fork guide pins into the corresponding shift drum grooves. • apply a little transmission oil to the shift rods, and slide them into the shift forks. • holding the shift drum with the suitable tool and tighten ...

  • Page 112

    7-16 engine bottom end/transmission transmission gear damage inspection • visually inspect the gear teeth on the transmission gears. Repair lightly damaged gear teeth with an oilstone. The gear must be replaced if the teeth are badly damaged. When gear is repaired or replaced, the driving gear shoul...

  • Page 113: Wheels/tires

    Wheels/tires 8-1 8 wheels/tires table of contents exploded view........................................................................................................................ 8-2 specifications ....................................................................................................

  • Page 114

    8-2 wheels/tires exploded view 1. Nipple 2. Spoke 3. Front tire 4. Rim 5. Front axle 6. Swingarm 7. Rear tire 8. Rear axle t1: 1.5 n·m (0.15 kgf·m, 13 in·lb) t2: 79 n·m (8.0 kgf·m, 58 ft·lb) g: apply grease. R: replacement parts wl: apply soap and water solution, or rubber lubricant..

  • Page 115

    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 2 mm radial 1.0 mm or less 2 mm axle runout/100 mm 0.1 mm 0.2 mm tires air pressure front and rear 98 kpa (1.0 kgf/cm², 14 psi) – – – tires standard ti...

  • Page 116

    8-4 wheels/tires wheels (rims) front wheel removal • using the jack [a] under the frame, and stabilize the mo- torcycle. Special tool - jack: 57001-1238 • place a stand under the engine to raise the front wheel the ground. • remove the cotter pin [a] • unscrew the axle nut [b]. • remove the axle [a]...

  • 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...

  • Page 118

    8-6 wheels/tires wheels (rims) • remove the cotter pin [a]. • remove the axle nut [b]. • pull out the axle [c]. • move the rear wheel back with the rear caliper installed. • take off the collar and cap from the each side of the rear hub. Notice do not lay the wheel on the ground with the disc facing...

  • 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...

  • 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 ...

  • Page 121

    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 and rider preference, but do not stray too far from the recom- mended pressure. Track condition ti...

  • Page 122

    8-10 wheels/tires tires tire removal notice do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground. • remove the wheel from the motorcycle (see wheels re- moval). • to maintain wheel balance, ...

  • Page 123

    Wheels/tires 8-11 tires tire installation • inspect the rim and tire, and replace them if necessary. • install the tube. • apply a soap and water solution, or rubber lubricant to the rim flange and tire beads. • position the tire on the rim so that the valve [a] is at the tire balance mark [b] (the ...

  • 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 circli...

  • 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 hole. • apply high temperature grease to the oil seal lips. Special tool - bearing driver set: 57001-1129 [c] inside circlip pliers...

  • Page 127: Final Drive

    Final drive 9-1 9 final drive table of contents exploded view........................................................................................................................ 9-2 specifications ......................................................................................................

  • Page 128

    9-2 final drive exploded view 1. Engine sprocket 2. Output shaft 3. Swingarm 4. Chain slipper 5. Chain guide 6. Locknut 7. Adjusting bolt 8. Chain adjuster 9. Drive chain 10. Rear sprocket 11. 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 gre...

  • 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 – – – type did 420mbk1 – – – length 108 links – – – 110 links (kx65-a3 ∼ ) – – – sprocket engine s...

  • 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 d...

  • 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. Warning a loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper tor...

  • 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 meas...

  • 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 t...

  • 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 tool - outside circlip pliers: 57001-144 engine sprocket installation • replace the circlip with a new one. • in...

  • Page 135

    Final drive 9-9 sprockets rear sprocket warp inspection • using the jack, raise the rear wheel off the ground. Special tool - jack: 57001-1238 • set a dial gauge [a] against the rear sprocket [b] near the teeth as shown and rotate [c] the rear wheel to measure the sprocket runout (warp). The differe...

  • Page 137: Brakes

    Brakes 10-1 10 brakes table of contents exploded view........................................................................................................................ 10-2 specifications .............................................................................................................

  • 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...

  • 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 in·lb) t4: 18 n·m (1.8 kgf·m...

  • Page 140

    10-4 brakes specifications item standard service limit brake adjustment lever play adjustable (to suit rider) – – – brake fluid recommended disc brake fluid: – – – type dot3 or dot4 – – – brake pads lining thickness: front 4.5 mm 0.7 mm rear 4.5 mm 0.7 mm brake disc thickness: front 2.80 ∼ 3.20 mm 2...

  • 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. Warning an improp...

  • Page 142

    10-6 brakes brake lever, brake pedal • remove the brake pedal mounting bolt [a] and take off the brake pedal and return spring [b]. Brake pedal installation • check the pedal o-ring for signs of damage. If necessary, replace them with new one. • apply high temperature grease to the shaft portion of ...

  • Page 143

    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...

  • 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 flu...

  • 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 ...

  • Page 146

    10-10 brakes brake fluid bleeding the brake line the brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake le...

  • Page 147

    Brakes 10-11 brake fluid • remove the clear plastic hose. • tighten the bleed valves, and install the rubber cap. Torque - caliper bleed valve: 7.8 n·m (0.8 kgf·m, 69 in·lb) • check the fluid level. • after bleeding is done, check the brake for good braking power, no brake drag, and no fluid leakage...

  • Page 148

    10-12 brakes caliper caliper removal front brake • loosen the banjo bolt [a] so as not to spill brake fluid. • remove the caliper mounting bolts [b]. • remove the banjo bolt and take off the brake hose from the caliper [c]. • if the caliper is to be disassembled after removal and if compressed air i...

  • 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, h...

  • 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). •...

  • Page 151

    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 i...

  • 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/in...

  • 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 [...

  • Page 154

    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 ...

  • Page 155

    Brakes 10-19 master cylinder master cylinder inspection (visual inspection) • disassemble the front and rear master cylinders. • check that there are no scratches, rust or pitting on the inner wall of each master cylinder [a] and on the outside of each piston [b]. If a master cylinder or piston show...

  • 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...

  • 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 par...

  • Page 159: Suspension

    Suspension 11-1 11 suspension table of contents exploded view........................................................................................................................ 11-2 specifications .....................................................................................................

  • Page 160

    11-2 suspension exploded view.

  • Page 161

    Suspension 11-3 exploded view 1. Top plug 2. O-ring 3. Fork spring 4. Piston cylinder unit 5. Inner tube 6. Guide bushes 7. Dust seal 8. Retaining ring 9. Oil seal 10. Washer 11. 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...

  • Page 162

    11-4 suspension exploded view.

  • Page 163

    Suspension 11-5 exploded view 1. Pivot shaft 2. Swingarm 3. Rocker arm 4. Tie-rod 5. Rear shock absorber 6. Rear shock absorber (kx65-a3 ∼ ) t1: 69 n·m (7.0 kgf·m, 51 ft·lb) t2: 83 n·m (8.5 kgf·m, 61 ft·lb) t3: 59 n·m (6.0 kgf·m, 43 ft·lb) t4: 34 n·m (3.5 kgf·m, 25 ft·lb) t5: 39 n·m (4.0 kgf·m, 29 f...

  • Page 164

    11-6 suspension specifications item standard service limit front fork oil viscosity showa 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) (fr...

  • Page 165

    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 the following methods. ○ oil level adjustment - the effects of higher or lower fork oil level are only felt during the final 100 mm of fork travel. A higher oil lev...

  • Page 166

    11-8 suspension front fork kx65-a3 ∼ • remove: number plate handlebar assembly front fork top 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 su...

  • Page 167

    Suspension 11-9 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 ∼ ). • tighten the fork top plug. Torque - front fork top plug: 22 n·m (2.2 kgf·m, 16 ft·lb) • assemble the oth...

  • Page 168

    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 top of the inner tube to the oil. Special tool - fork oil level gauge: 57001-1290 oil level (fully compressed, without spring) stan...

  • Page 169

    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 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...

  • Page 170

    11-12 suspension front fork • remove the cylinder unit [a] and spring [b] from the fork. • remove the dust seal [a] and retaining ring [b]. • use the fork outer tube weight [a] to separate the inner tube from the outer tube. Special tool - fork outer tube weight: 57001-1218 ○ holding the inner tube ...

  • Page 171

    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 bushes oil seal bottom allen bolt gasket • inspect the following and replace them with new ones if damaged. Inner tube (see inner tube ins...

  • Page 172

    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 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. Sin...

  • Page 173

    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 and rocker arm. To suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spr...

  • Page 174

    11-16 suspension rear suspension (uni-trak) • 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 tool - hook wrench: 57001-1101 spring preload adjustment (adjusting nut position [a] from the ...

  • Page 175

    Suspension 11-17 rear suspension (uni-trak) • remove the rear shock absorber upper mounting bolt [a], and pull out the rear shock absorber [b]. Rear shock absorber installation • pack the rocker arm needle bearings with grease. • tighten the following: torque - rear shock absorber mounting bolt (upp...

  • Page 176

    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 and lift off the spring [c]. • install the spring guide. • adjust the spring preload (see spring preload adjust- ment). • in...

  • Page 177

    Suspension 11-19 swingarm swingarm removal • place the jack under the frame so that the rear wheel is off the ground. Special tool - jack: 57001-1238 • remove the rear wheel (see wheels/tires chapter). • remove the brake pedal [a]. • remove the tie-rod rear mounting bolt [b]. Notice when pulling out...

  • Page 178

    11-20 suspension swingarm swingarm bearing installation • replace the needle bearings, dust seals and oil seals with new ones. • apply plenty of grease to the dust seals, oil seals and needle bearings. Note ○ install the needle bearings so that the manufacturer’s marks face out. Special tool - beari...

  • Page 179

    Suspension 11-21 tie-rod, rocker arm tie-rod removal • using the jack under the frame, raise the rear wheel off the ground. Special tool - jack: 57001-1238 • remove the tie-rod front mounting bolt [a]. Notice when pulling out the mounting bolts, lift the rear wheel slightly. Forcing or tapping on a ...

  • Page 180

    11-22 suspension tie-rod, rocker arm rocker arm installation • apply plenty of grease to the inside of the rocker arm holes, needle bearings, oil seals and grease seals out- side of the sleeve. • install the needle bearing [a], grease seals [b] and oil seals [c] position as shown. • tighten the foll...

  • Page 181

    Suspension 11-23 uni-trak maintenance check the uni-trak component parts for wear periodically, or whenever excessive play is suspected. • using the jack under the frame, raise the rear wheel off the ground. Special tool - jack: 57001-1238 • push and pull on the swingarm [a], up and down, to check f...

  • Page 183: Steering

    Steering 12-1 12 steering table of contents exploded view........................................................................................................................ 12-2 specifications .........................................................................................................

  • 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. Tapered roller bearing 7. Head pipe 8. Tapered 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....

  • Page 185

    Steering 12-3 specifications special tools - steering stem bearing driver: 57001-137 head pipe outer race press shaft: 57001-1075 steering stem bearing driver adapter: 57001-1092 steering stem nut wrench: 57001-1100 head pipe outer race driver: 57001-1106 head pipe outer race remover: 57001-1107 jac...

  • Page 186

    12-4 steering steering steering inspection • using the jack, raise the front wheel off the ground. Special tool - jack: 57001-1238 • with the front wheel pointing straight ahead, alternately nudge each end of the handlebar. The front wheel should swing fully left and right from the force of gravity ...

  • Page 187

    Steering 12-5 steering steering stem, stem bearing removal • remove: front wheel (see wheels/tires chapter) brake hose clamp (see brake system chapter) caliper mounting bolts (see brake system chapter) master cylinder clamp (see brake system chapter) front fender handlebar (see handlebar removal) fr...

  • 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 tools - head pipe outer race press shaft: 57001 -1075 head pipe ...

  • Page 189

    Steering 12-7 steering torque - steering stem head nut: 44 n·m (4.5 kgf·m, 33 ft·lb) front fork clamp bolt: upper: 20 n·m (2.0 kgf·m, 15 ft·lb) lower: 29 n·m (3.0 kgf·m, 22 ft·lb) • install the parts removed (see the appropriate chapter). Warning do not impede the handlebar turning by routing the ca...

  • 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, cl...

  • 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 maste...

  • Page 193: Electrical System

    Electrical system 13-1 13 electrical system table of contents wiring diagram....................................................................................................................... 13-2 exploded view.........................................................................................

  • Page 194

    13-2 electrical system wiring diagram kx65a6f ∼.

  • Page 195

    Electrical system 13-3 exploded view 1. Magneto cover 2. Magneto flywheel 3. Stator 4. Cdi unit 5. Ignition coil 6. Spark plug cap 7. Spark plug 8. Engine stop button 9. Kx65-a1 ∼ a6 t1: 29 n·m (3.0 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 (0.9...

  • Page 196

    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°...

  • 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 ...

  • 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...

  • Page 199

    Electrical system 13-7 ignition timing ignition timing adjustment • remove the magneto cover. • check to see if the center mark of the three marks [a] on the magneto stator plate is aligned with the mark [b] on the crankcase. If the marks are not aligned, loosen the magneto stator plate mounting scr...

  • Page 200

    13-8 electrical system flywheel magneto flywheel magneto removal • remove the magneto cover. • hold the flywheel steady, with the flywheel & pulley holder [a], and remove the flywheel nut [b]. Special tool - flywheel & pulley holder: 57001-1343 • screw the flywheel puller [a] into the flywheel by tu...

  • 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 woodruff key [a] securely in the slot in the crank- shaft before installing the sta...

  • Page 202

    13-10 electrical system flywheel magneto • to check the stator coil resistance as follows. ○ connect the hand tester to the terminals of the harness connector [a] as shown in the table 2. ○ note the readings. Table 2 stator coil resistance connections tester range tester (+) tester (–) to reading × ...

  • Page 203

    Electrical system 13-11 ignition system safety instructions warning the ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Crankshaft sensor installation (k...

  • Page 204

    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 blac...

  • Page 205

    Electrical system 13-13 ignition system warning to avoid extremely high voltage shocks, do not touch the coil or lead. If the distance reading is less than the specified value, the ignition coil or spark plug cap is defective. 3 needle arcing distance standard: 7 mm or more • to determine which part...

  • 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, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high flash-point solvent and a wir...

  • Page 207

    Electrical system 13-15 ignition system ignition coil primary peak voltage check • remove: shrouds side covers seat fuel tank • disconnect the spark plug cap from the spark plug [a]. • connect the new spark plug [b] to the spark plug cap, then ground it to the engine. Note ○ measure the voltage with...

  • Page 208

    13-16 electrical system ignition system.

  • Page 209

    Electrical system 13-17 ignition system exciter (stator) coil peak voltage check • disconnect the connector of the harness from the cdi unit. • to check the peak voltage, do the following procedures. Note ○ measure the voltage with each lead connected cor- rectly. The correct value may not be obtain...

  • Page 211: Appendix

    Appendix 14-1 14 appendix table of contents troubleshooting guide ........................................................................................................... 14-2 general lubrication ........................................................................................................

  • Page 212

    14-2 appendix troubleshooting guide note ○ this is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine doesn’t start, starting difficulty: engine won’t turn ove...

  • Page 213

    Appendix 14-3 troubleshooting 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 clogg...

  • Page 214

    14-4 appendix troubleshooting 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 lev...

  • Page 215

    Appendix 14-5 troubleshooting 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: (too hard) front fork oil excessive front fork oil...

  • 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 u...

  • 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 temperatu...

  • Page 218

    14-8 appendix unit conversion table prefixes for units: prefix symbol power mega m × 1 000 000 kilo k × 1 000 centi c × 0.01 milli m × 0.001 micro µ × 0.000001 units of mass: kg × 2.205 = lb g × 0.03527 = oz units of volume: l × 0.2642 = gal (us) l × 0.2200 = gal (imp) l × 1.057 = qt (us) l × 0.8799...

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    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 ...