Chicago Electric 94626 Cordless Saw User Manual

Quick Reference Guide
General Information
1 j
Fuel System
2 j
Cooling System
3 j
Engine Top End
4 j
Engine Right Side
5 j
Engine Removal/Installation
6 j
Engine Bottom End/Transmission 7 j
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number 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 specific topic required.
Wheels/Tires
8 j
Final Drive
9 j
Brakes
10 j
Suspension
11 j
Steering
12 j
Electrical System
13 j
Appendix
14 j
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 Division/Consumer Products & Machinery Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 1999 Kawasaki Heavy Industries, Ltd.
8th Edition (1) : Apr. 21, 2006 (K)
LIST OF ABBREVIATIONS
A
ABDC
AC
ATDC
BBDC
BDC
BTDC
°C
DC
F
°F
ft
g
h
L
ampere(s)
after bottom dead center
alternating current
after top dead center
before bottom dead center
bottom dead center
before top dead center
degree(s) Celsius
direct current
farad(s)
degree(s) Fahrenheit
foot, feet
gram(s)
hour(s)
liter(s)
lb
m
min
N
Pa
PS
psi
r
rpm
TDC
TIR
V
W
Ω
pound(s)
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
revolution
revolution(s) per minute
top dead center
total indicator reading
volt(s)
watt(s)
ohm(s)
This motorcycle is designed for a rider weighing less than 121 pounds (55 kg). Exceeding this
limit could damage the motorcycle.
Read OWNER’S MANUAL before operating.
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts as to his ability to do the work, all adjustments, maintenance, and repair should be
carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work carefully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may adversely affect safe operation.
To get the longest life out of your motorcycle:
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki motorcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki Motorcycles are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
Follow the procedures in this manual carefully. Don’t take shortcuts.
Remember to keep complete records of maintenance and repair with dates and any new
parts installed.
•
•
•
•
•
How to Use this Manual
In this manual, the product is divided into its
major systems and these systems make up the
manual’s chapters.
The Quick Reference Guide shows you all
of the product’s system and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
Foe Example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use
the Table of Contents on the first page of the
chapter to find the ignition coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in personal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in damage to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.
NOTE
This
note
symbol
indicates points of par○
ticular interest for more efficient and convenient operation.
a procedural step or work to be
• Indicates
done.
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
General Information
1
Table of Contents
Before Servicing .....................................................................................................................
Model Identification.................................................................................................................
General Specifications............................................................................................................
Periodic Maintenance Chart ...................................................................................................
Torque and Locking Agent......................................................................................................
Special Tools and Sealants ....................................................................................................
Cable, Wire and Hose Routing ...............................................................................................
1-2
1-5
1-6
1-9
1-11
1-14
1-18
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
(1) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten
the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or
metal filings.
(2) Battery Ground
Disconnect the ground (–) cable from the battery before performing any disassembly operations
on the motorcycle. This prevents the engine from accidentally turning over while work is being
carried out, sparks from being generated while disconnecting the cables from electrical parts, as
well as damage to the electrical parts themselves. For reinstallation, first connect the positive
cable to the positive (+) terminal of the battery
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly sequence is given in this Service Manual, follow it. Note parts locations and
cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever
possible.
(4) Tightening Sequence
When installing bolts, nuts, or screws for which a tightening sequence is given in this Service
Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or
screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has
been installed in its proper location. Then, tighten them to the specified torque in the tightening
sequence and method indicated. If tightening sequence instructions are not given, tighten them
evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws
that are retaining the part a 1/4-turn before removing them.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage. Use a good quality, reliable torque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removing screws held by non-permanent locking
agent) in order to avoid damaging the screw heads.
(7) Edges
Watch for sharp edges, as they could cause injury through careless handling, especially during
major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine
or turning it over.
(8) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is standard solvent (generic name). Always follow manufacturer
and container directions regarding the use of any solvent.
(9) Gasket, O-ring
Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter
from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent
oil or compression leaks.
(10)Liquid Gasket, Locking Agent
Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used.
Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage.
GENERAL INFORMATION 1-3
Before Servicing
(11) Press
When using a press or driver to install a part such as a wheel bearing, apply a small amount of
oil to the area where the two parts come in contact to ensure a smooth fit.
(12)Ball Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any
ball or needle bearings that were removed with new ones. Install bearings with the manufacturer
and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the
end of the race that contacts the press fit portion, and press it evenly over the base component.
(13)Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a
force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless
instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s marks,
press it in with the marks facing out.
(14)Circlip, Retaining Ring, and Cotter Pin
When installing circlips and retaining rings, take care to compress or expand them only enough
to install them and no more. Install the circlip with its chamfered side facing load side as well.
Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while
the motorcycle is driven, leading to a major problem.
(15)Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the sliding
surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding
surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative
quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off
and apply fresh grease or oil. Some oils and greases in particular should be used only in certain
applications and may be harmful if used in an application for which they are not intended.
(16)Direction of Engine Rotation
To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper
adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as
well.
(17)Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed.
Replacement parts will be damaged or lose their original function once they are removed. Therefore, always replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and
cotter pin have not been so designated in their respective text, they are replacement parts.
(18)Electrical Leads
All the electrical leads are either one-color or two-color. A two-color lead is identified first by
the primary color and then the stripe color. For example, a yellow lead with thin red stripes is
referred to as a “yellow/red” lead; it would be a “red/yellow” lead if the colors were reversed.
Unless instructed otherwise, electrical leads must be connected to leads of the same color.
Two-Color Electrical
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
Bent
Color change
Crack
Dent
Deterioration
Hardening
Scratch
Seizure
Warp
Wear
(20)Specifications
Specification terms are defined as follows:
"Standards" show dimensions or performances which brand-new parts or systems have.
"Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.
GENERAL INFORMATION 1-5
Model Identification
KX65-A1 Left Side View
KX65-A1 Right Side View
1-6 GENERAL INFORMATION
General Specifications
Items
Dimensions
Overall Length
Overall Width
Overall Height
Wheelbase
Road Clearance
Seat Height
Dry Mass
Curb Mass:
Front
Rear
Fuel Tank Capacity
Engine
Type
Cooling System
Bore and Stroke
Displacement
Compression Ratio
Carburetion System
Starting System
Ignition System
Ignition Timing
Spark Plug
Port Timing
Inlet:
Open
Close
Scavenging:
Open
Close
Duaration
Exhaust:
Open
Close
Duaration
Lubrication System
(Gasoline : Oil)
KX65-A1 ∼ A2
1 580 mm
690 mm (KX65-A1), 730 mm (KX65-A2)
925 mm (KX65-A1), 935 mm (KX65-A2)
1 110 mm
270 mm (KX65-A1), 280 mm (KX65-A2)
720 mm (KX65-A1), 730 mm (KX65-A2)
53 kg
26.5 kg
29.5 kg
3.8 L
2-stroke, single cylinder, piston reed valve
Liquid-cooled
44.5 × 41.6 mm
64 cm³
8.4: 1
MIKUNI VM24SS
Primary kick
MAGNETO CDI
20.5° BTDC @6 000 r/min (rpm)
NGK BR10EG (US) NGK B10EG
KX65-A3 ∼ A6, A6F ∼
1 590 mm
760 mm
955 mm
1 120 mm
305 mm
760 mm
57 kg
28.5 kg
31.5 kg
←
←
←
←
←
←
←
←
←
←
20.5ºBTDC
@7 100 r/min (rpm)
(KX65A6F ∼)
←
NGK BR10EG
(KX65A6F ∼)
Full open
—
←
←
61.8° BBDC
61.8° ABDC
123.6°
←
←
←
91.5° BBDC
91.5° ABDC
183°
Petrol mix (32:1)
←
←
←
←
GENERAL INFORMATION 1-7
General Specifications
Items
Drive Train
Primary Reduction System:
Type
Reduction Ratio
Clutch Type
Transmission:
Type
Gear Ratios:
1st
2nd
3rd
4th
5th
6th
Final Drive System:
Type
Reduction Ratio
Overall Drive Ratio
Transmission Oil:
Grade
Viscosity
Capacity
Frame
Type
Steering Angle
Caster (Rake Angle)
Trail
Front Tire:
Size
Type
Rear Tire:
Size
Type
Rim Size:
Front
Rear
Front Suspension:
Type
Wheel Travel
Rear Suspension:
Type
Wheel Travel
KX65-A1 ∼ A2
KX65-A3 ∼ A6, A6F ∼
Gear
3.500 (77/22)
Wet, multi disc
←
←
←
6-speed, constant mesh, return shift
←
2.846
2.125
1.722
1.428
1.217
1.083
(37/13)
(34/16)
(31/18)
(30/21)
(28/23)
(26/24)
←
←
←
←
←
←
Chain drive
3.538 (46/13)
13.416 @Top gear
←
3.615 (47/13)
13.703 @Top gear
API SE, SF or SG
API SH or SJ with JASO MA
←
API SH, SJ or SL
with JASO MA
←
←
SAE 10W-40
0.5 L
Tubular, semi-double cradle
40° to either side
26.5°
60 mm
←
←
27°
←
60/100-14 30M
tube type
←
←
80/100-12 41M
tube type
←
←
14 × 1.40
12 × 1.60
←
←
Telescopic fork
210 mm
←
←
Swingarm (Uni-trak)
225 mm
←
240 mm
1-8 GENERAL INFORMATION
General Specifications
Items
Brake Type:
Front and Rear
Effective Disc Diameter:
Front
Rear
KX65-A1 ∼ A2
Single disc
164.8 mm
146 mm
KX65-A3 ∼ A6, A6F ∼
←
←
←
←
Specifications are subject to change without notice, and may not apply to every country.
US: United States Model
GENERAL INFORMATION 1-9
Periodic Maintenance Chart
The maintenance must be done in accordance with this chart to keep the motorcycle in good running
condition.
FREQUENCY
OPERATION
Clutch - adjust
Clutch and friction plates - inspect †
Throttle cable - adjust
Spark plug - clean, gap †
Air cleaner element - clean
Air cleaner element - replace
Carburetor - inspect/adjust
Transmission oil - change
After
Every
Every
Every
3 races 5 races 10 races
As
each
race (or (or 7.5 (or 12.5 (or 25 required
2.5 hr.)
hr.)
hr.)
hr.)
•
•
•
•
•
Piston and piston ring - clean/inspect †
Cylinder head, cylinder - inspect
Muffler body - clean/inspect †
Muffler body packing - change
•
Small end bearing - inspect †
Kick pedal and shift pedal - clean
Exhaust pipe O-ring - replace
Engine sprocket - inspect †
Coolant - inspect †
Water hoses, connections - inspect †
Reed valve - inspect †
Brake adjustment - inspect †
Brake pad wear - inspect †
•
•
•
•
•
•
Brake fluid - change
Brake master cylinder cup and dust seal - replace
Brake caliper fluid seal and dust seal - replace
Brake hose - replace
Spoke tightness and rim runout - inspect †
Drive chain - adjust
Drive chain - lubricate
Drive chain wear - inspect †
•
•
•
•
Drive chain slipper and guide - replace
Front fork - inspect/clean
R
R
When damaged
•
•
•
R
•
•
R
•
R
•
Brake fluid level - inspect †
Brake hoses, connections - inspect †
•
•
Every
Every
Every
Every
2
2
2
4
years
years
years
years
•
When damaged
•
Front fork oil - change
1st time after 2 races, then every 5 races
Nuts, bolts, fasteners - inspect †
•
•
Fuel system - clean
Fuel hose - replace
Every 4 years
1-10 GENERAL INFORMATION
Periodic Maintenance Chart
FREQUENCY
OPERATION
Fuel hoses, connections - inspect †
Steering play - inspect †
Steering stem bearing - grease
After
Every
Every
Every
As
each
3 races 5 races 10 races
race (or (or 7.5 (or 12.5 (or 25 required
2.5 hr.)
hr.)
hr.)
hr.)
•
•
Rear sprocket - inspect †
General lubrication - perform
Wheel bearing - inspect †
•
Swing arm and Uni-Trak linkage pivots - grease
Swing arm and Uni-Trak linkage pivots - inspect †
Rear shock oil - replace
•
•
•
•
•
1st time after 2 races, then every 5 races
†: Replace, add, adjust, clean or torque if necessary.
R: Replace
GENERAL INFORMATION 1-11
Torque and Locking Agent
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently
tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The
following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a
non-permanent locking agent or liquid gasket.
When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn
and then tighten to specified torque.
Letters used in the "Remarks" column mean:
L: Apply a non-permanent locking agent to the threads.
Lh: Left-hand Threads.
S: Tighten the fasteners following the specified sequence.
Fastener
Fuel System
Rear Frame Mounting Bolts
Carburetor Clamp Screws
Carburetor Holder Mounting Bolts
Air Cleaner Housing Plate Nuts
Air Cleaner Housing Mounting Bolts
Reed Valve Screws
Cooling System
Radiator Mounting Bolts
Shroud Mounting Bolts
Air Bleeder Bolt
Water Pump Cover Bolts
Water Pump Impeller Bolt
Water Hose Clamp Screws
Coolant Drain Plug (Water Pump)
Water Pump Cover Fitting Bolts
Engine Top End
Cylinder Head Nuts
Spark Plug
Cylinder Nuts
Muffler Mounting Bolts
Expansion Chamber Damper Mounting Bolt,
Nut
Inner Pipe Mounting Bolts
Engine Right Side
Primary Gear Nut (KX65A6F ∼)
Clutch Spring Bolts
Clutch Hub Bolt
Ratchet Guide Bolt
Ratchet Guide Screw
Kick Pedal Bolt
Right Engine Cover Bolts
Oil Filler Cap
Gear Set Lever Screw
N·m
Torque
kgf·m
ft·lb
34
1.5
8.8
3.0
8.8
9.8
3.5
0.15
0.90
0.31
0.90
1.0
25
13 in·lb
78 in·lb
27 in·lb
78 in·lb
87 in·lb
8.8
8.8
8.8
8.8
8.3
1.5
8.8
5.9
0.90
0.90
0.90
0.90
0.85
0.15
0.90
0.60
78
78
78
78
73
13
78
52
25
26
25
8.8
2.5
2.6
2.5
0.90
18
19
18
78 in·lb
8.8
0.90
78 in·lb
5.9
0.6
52 in·lb
L
49
9.3
64
8.8
5.2
12
8.8
1.5
8.8
5.0
0.95
6.5
0.90
0.53
1.2
0.90
0.15
0.90
36
82 in·lb
47
78 in·lb
46 in·lb
104 in·lb
78 in·lb
13 in·lb
78 in·lb
Lh
Remarks
in·lb
in·lb
in·lb
in·lb
in·lb
in·lb
in·lb
in·lb
L
1-12 GENERAL INFORMATION
Torque and Locking Agent
Fastener
Engine Removal/Installation
Engine Mounting Nuts
Engine Mounting Nuts (KX65-A3 ∼)
Swing Arm Pivot Shaft Nut
Engine Bottom End/Transmission
Cylinder Stud
Crankcase Bolts
Shift Pedal Bolt
Engine Oil Drain Plug
Bearing Retaining Screws
Shift Drum Operating Plate Bolt
Shift Drum Plate Mounting Screws
Gear Set Lever Screw
Flywheel Nut
Wheels/Tires
Front Axle Nut
Rear Axle Nut
Spoke Nipple
Final Drive
Rear Axle Nut
Rear Sprocket Bolts
Brakes
Caliper Mounting Bolts (Front, Rear)
Brake Hose Banjo Bolts
Master Cylinder Clamp Bolts
Rear Master Cylinder Mounting Screws
Rear Master Cylinder Push Rod Locknut
Brake Disc Mounting Bolts (Front, Rear)
Caliper Bleed Valves (Front, Rear)
Brake Pedal Mounting Bolt
Brake Lever Adjuster locknut
Brake Pad Bolts
Suspension
Front Fork Clamp Bolts (Upper)
Front Fork Clamp Bolt (Lower)
Fork Bottom Allen Bolt
Front Fork Top Plug
Swingarm Pivot Shaft Nut
Rear Shock Absorber Mounting Bolt (Upper)
Rear Shock Absorber Mounting Nut (Lower)
Tie-rod Mounting Nuts (Front, Rear)
N·m
Torque
kgf·m
ft·lb
25
29
69
2.5
3.0
7.0
18
21
51
–
–
–
8.8
8.8
20
8.8
24
5.2
8.8
29
0.90
0.90
2.0
0.90
2.4
0.53
0.90
3.0
78 in·lb
78 in·lb
15
78 in·lb
17
46 in·lb
78 in·lb
21
79
79
Not less
than 1.5
8.0
8.0
Not less
than 0.15
58
58
Not less
than 13
in·lb
79
26
8.0
2.7
58
20
25
25
8.8
9.8
18
9.8
7.8
25
4.9
18
2.5
2.5
0.90
1.0
1.8
1.0
0.80
2.5
0.50
1.8
18
18
78 in·lb
87 in·lb
13
87 in·lb
69 in·lb
18
43 in·lb
13
20
29
20
22
69
39
34
59
2.0
3.0
2.0
2.2
7.0
4.0
3.5
6.0
14
22
14
16
51
29
25
43
Remarks
L (Planted
Side)
L
L
S
L
L
GENERAL INFORMATION 1-13
Torque and Locking Agent
Fastener
Rocker Arm Pivot Nut
Caliper Mounting Bolts
Rear Frame Mounting Bolts
Steering
Steering Stem Head Nut
Steering Stem Nut
Handlebar Clamp Bolts
Clutch Lever Clamp Bolts
Front Fork Clamp Bolts (Upper)
Front Fork Clamp Bolts (Lower)
Electrical System
Magneto Cover Bolts
Flywheel Nut
Stator Plate Mounting Screws
Ignition Coil Mounting Bolts
CDI Unit Mounting Bolts
Spark Plug
N·m
83
25
34
Torque
kgf·m
8.5
2.5
3.5
ft·lb
61
18
25
44
2.9
25
8.8
20
29
4.5
0.30
2.5
0.90
2.0
3.0
33
26 in·lb
18
78 in·lb
15
22
8.8
29
4.9
8.8
8.8
26
0.90
3.0
0.50
0.90
0.90
2.6
78 in·lb
21
43 in·lb
78 in·lb
78 in·lb
19
Remarks
The table below relating tightening torque to thread diameter, lists the basic torque the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads dia.
(mm)
5
6
8
10
12
14
16
18
20
N·m
3.4 ∼ 4.9
5.9 ∼ 7.8
14 ∼ 19
25 ∼ 34
44 ∼ 61
73 ∼ 98
115 ∼ 155
165 ∼ 225
225 ∼ 325
Torque
kgf·m
0.35 ∼ 0.50
0.60 ∼ 0.80
1.4 ∼ 1.9
2.6 ∼ 3.5
4.5 ∼ 6.2
7.4 ∼ 10.0
11.5 ∼ 16.0
17 ∼ 23
23 ∼ 33
ft·lb
30 ∼ 43 in·lb
52 ∼ 69 in·lb
10.0 ∼ 13.5
19.0 ∼ 25
33 ∼ 45
54 ∼ 72
83 ∼ 115
125 ∼ 165
165 ∼ 240
1-14 GENERAL INFORMATION
Special Tools and Sealants
Bearing Puller Adapter:
57001-136
Fork Cylinder Holder Handle:
57001-183
Steering Stem Bearing Driver:
57001-137
Flywheel Puller, M12 × 1.75:
57001-252
Inside Circlip Pliers:
57001-143
Piston Pin Puller Assembly:
57001-910
Outside Circlip Pliers:
57001-144
Fork Cylinder Holder Adapter:
57001-1011
Bearing Puller:
57001-158
Oil Seal & Bearing Remover:
57001-1058
GENERAL INFORMATION 1-15
Special Tools and Sealants
Rim Protector:
57001-1063
Hook Wrench R37.5, R42:
57001-1101
Bead Breaker Assembly:
57001-1072
Head Pipe Outer Race Driver,
57001-1106
Head Pipe Outer Race Press Shaft:
57001-1075
Head Pipe Outer Race Remover ID > 37 mm:
57001-1107
Steering Stem Bearing Driver Adapter,
57001-1092
Steering Stem Nut Wrench:
57001-1100
29.7:
Bearing Driver Set:
57001-1129
Fork Outer Tube Weight:
57001-1218
46.5:
1-16 GENERAL INFORMATION
Special Tools and Sealants
Front Fork Oil Seal Driver:
57001-1219
Peak Voltage Adapter:
57001-1415
Jack:
57001-1238
Crank Shaft Jig:
57001-1439
Fork Oil Level Gauge:
57001-1290
Graduated Cylinder & Tube:
57001-1584
Crankcase Splitting Tool Assembly:
57001-1362
Flywheel & Pulley Holder:
57001-1605
Hand Tester:
57001-1394
Fuel Level Gauge Adapter, M16 × 1:
57001-1661
GENERAL INFORMATION 1-17
Special Tools and Sealants
Kawasaki Bond (Silicone Sealant):
56019-120
Kawasaki Bond (Liquid Gasket - Silver):
92104-002
1-18 GENERAL INFORMATION
Cable, Wire and Hose Routing
1. Throttle 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 figure.
7. CDI Unit (KX65-A1 ∼ A6)
8. Clamp
9. Rubber Damper (Note its installing direction.)
10. Clutch Cable
11. Engine Stop Button Lead
12. Band
13. Install the kick pedal so that it should be
parallel to the frame as shown in figure.
14. KX65-A1 ∼ A2
15. KX65-A3 ∼ A6
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 figure.
9. Cylinder Head
10. Cylinder
11. Water Pump Cover
12. Engine Stop Button Lead (KX65A6F ∼)
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. Engine Stop Button Lead Ground
11. CDI Unit Ground Lead
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 joint pin.
12. White paint mark
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
FUEL SYSTEM 2-1
Fuel System
2
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Throttle Grip and Cable ..........................................................................................................
Free Play Inspection .........................................................................................................
Free Play Adjustment........................................................................................................
Throttle Cable Installation .................................................................................................
Cable Lubrication ..............................................................................................................
Cable Inspection ...............................................................................................................
Carburetor ..............................................................................................................................
Idle Speed Inspection .......................................................................................................
Idle Speed Adjustment......................................................................................................
Service Fuel Level Inspection ...........................................................................................
Service Fuel Level Adjustment .........................................................................................
Carburetor Removal..........................................................................................................
Carburetor Installation.......................................................................................................
Fuel Inspection..................................................................................................................
Carburetor Disassembly ...................................................................................................
Carburetor Assembly ........................................................................................................
Carburetor Cleaning..........................................................................................................
Carburetor Inspection .......................................................................................................
Air Cleaner..............................................................................................................................
Air Cleaner Housing Removal...........................................................................................
Air Cleaner Housing Installation........................................................................................
Element Removal..............................................................................................................
Element Installation...........................................................................................................
Element Cleaning and Inspection .....................................................................................
Fuel Tank ................................................................................................................................
Fuel Tank Removal ...........................................................................................................
Fuel Tank Installation ........................................................................................................
Fuel Tap Removal .............................................................................................................
Fuel Tap Installation ..........................................................................................................
Fuel Tap Inspection...........................................................................................................
Fuel Tank and Tap Cleaning .............................................................................................
Reed Valve .............................................................................................................................
Reed Valve Removal ........................................................................................................
Reed Valve Installation .....................................................................................................
Reed Valve Inspection ......................................................................................................
Fuel Hose ...............................................................................................................................
Fuel Hoses and Connections Check.................................................................................
2-2
2-4
2-5
2-5
2-5
2-5
2-6
2-6
2-7
2-7
2-7
2-7
2-8
2-9
2-10
2-11
2-11
2-12
2-12
2-13
2-15
2-15
2-15
2-15
2-15
2-16
2-17
2-17
2-17
2-17
2-17
2-18
2-18
2-19
2-19
2-19
2-19
2-20
2-20
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
18. Reed Valve
T1: 8.8 N·m (0.90 kgf·m, 78 in·lb)
T2: 1.5 N·m (0.15 kgf·m, 13 in·lb)
T3: 9.8 N·m (1.0 kgf·m, 87 in·lb)
G: Apply grease.
O: Apply oil.
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
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
2-4 FUEL SYSTEM
Specifications
Item
Standard
KX65-A1 ∼ A2
KX65-A3 ∼
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 groove from the top 3rd groove from the top
Needle Jet
O-0
←
Slow Jet
#40
#25
Air Screw
2 (turns out)
1 1/2 (turns out)
Main Air Jet
0.8 (Pressed in)
←
0.5 ±1 mm
←
Service Fuel Level (below the
Bottom Edge of the Carburetor
Body)
Float Height
21.1 ±1 mm
←
Air Cleaner
Element Oil
High-quality foam-air filter oil
Reed Valve
Reed Warp
– – –
Special Tools - Fuel Level Gauge Adapter M16 × 1: 57001-1661
Graduated Cylinder & Tube: 57001-1584
Service
Limit
–––
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–––
–––
0.5 mm
FUEL SYSTEM 2-5
Throttle Grip and Cable
If the throttle grip has excessive free play due to cable
stretch or mis-adjustment, there will be a delay in throttle
response. Also, the throttle valve may not open fully at full
throttle. On the other hand, if the throttle grip has no play,
the throttle will be hard to control, and the idle speed will
be erratic. Check the throttle grip play periodically in accordance with the Periodic Maintenance Chart, and adjust the
play if necessary.
The throttle cable routing is shown in Cable, Wire and
Hose Routing in the General Information chapter.
Free Play Inspection
the throttle grip free play [B] by lightly turning the
• Check
throttle grip [A] back and forth.
If the free play is improper, adjust the throttle cable.
Throttle Grip Free Play
2 ∼ 3 mm
Standard:
Free Play Adjustment
the locknut [A] at the upper end of the throttle
• Loosen
cable.
the adjuster [B] until the proper amount of throttle
• Turn
grip free play is obtained.
• Tighten the locknut.
•
•
If the throttle grip free play cannot be adjusted with the
adjuster at the upper end of the throttle cable, use the
cable adjuster [A] at the carburetor.
Pull the boot off of the carburetor top. Make the necessary
free play adjustment at the lower cable adjuster, tighten
the locknut [B], and install the boot.
Turn the handlebar from side to side while idling the engine. If idle speed varies, the throttle cable may be poorly
routed or it may be damaged.
WARNING
Operation with an improperly adjusted, incorrectly
routed, or damaged cable could result in an unsafe
riding condition.
Throttle Cable Installation
the throttle cable in accordance with the Cable,
• Install
Wire and Hose Routing section in the General Informa-
•
tion chapter.
After the installation, adjust each cable properly.
WARNING
Operation with an incorrectly routed or improperly
adjusted cable could result in an unsafe riding condition.
2-6 FUEL SYSTEM
Throttle Grip and Cable
Cable Lubrication
Whenever the cable is removed, and in accordance with
the Periodic Maintenance Chart (see General Information
chapter), do the following.
Apply a thin coating of grease [A] to the cable upper end.
•
• Lubricate the cable [A] with a penetrating rust inhibitor.
Cable Inspection
the throttle cable [A] disconnected at both ends, the
• With
cable should move freely within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed, or if the housing is kinked, replace the cable.
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 carburetor 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 or damaged air cleaner can also alter the
fuel to air ratio.
Idle Speed Inspection
the engine and warm it up thoroughly.
• Start
the engine idling, turn the handlebar to both sides.
• With
If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted or incorrectly routed,
or it may be damaged. Be sure to correct any of these
conditions before riding (see Cable, Wire and Hose Routing in the General Information chapter).
WARNING
Operation with an improperly adjusted, incorrectly
routed, or damaged cable could result in an unsafe
riding condition.
idle speed.
• Check
Adjust it as needed.
Idle Speed Adjustment
turn in the air screw [A] until it seats lightly, and back
• First
it out 2 turns (KX65-A1 ∼ A2).
turn in the air screw [A] until it seats lightly, and back
• First
out 1 1/2 turns (KX65-A3 ∼).
the engine and warm it up thoroughly.
• Start
Turn
adjusting screw [B] to obtain desired idle
• speed.theIf idle
no idle is preferred, turn out the screw until the
•
engine stops.
Open and close the throttle a few times to make sure that
the idle speed is as desired. Readjust if necessary.
Service Fuel Level Inspection
WARNING
Gasoline is extremely flammable and can be explosive 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.
the fuel tap to the OFF position.
• Turn
Remove
the fuel tank (see Fuel Tank Removal).
•
2-8 FUEL SYSTEM
Carburetor
the carburetor, and hold it in true vertical position
• Remove
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 float bowl,
and screw a fuel level gauge adapter [B] into the drain
plug hole.
Connect of the graduated cylinder & tube [C] to fuel level
gauge adapter.
Special Tools - Fuel Level Gauge Adapter M16 × 1: 57001
-1661
Graduated Cylinder & Tube: 57001-1584
the gauge vertically against the side of the carbure• Hold
tor body so that the "zero" line [D] is several millimeters
•
•
•
higher than the bottom edge [E] of the carburetor body.
Turn the fuel tap to the ON position to feed fuel to the
carburetor.
Wait until the fuel level in the gauge settles.
Keeping the gauge vertical, slowly lower the gauge until
the "zero" line is even with the bottom edge of the carburetor body.
NOTE
○Do not lower the "zero" line below the bottom edge of
the carburetor body. If the gauge is lowered and then
raised again, the fuel level measure shows somewhat
higher than the actual fuel level. If the gauge is lowered
too far, dump the fuel out of it into a suitable container
and start the procedure over again.
the fuel level in the gauge and compare it to the
• Read
specification.
Service Fuel Level (below the bottom edge of the carb.
body)
Standard:
0.5 ±1 mm
•
•
If the fuel level is incorrect, adjust it.
Turn the fuel tap to the OFF position and remove the fuel
level gauge.
Install the drain plug on the bottom of the float bowl.
Service Fuel Level Adjustment
WARNING
Gasoline is extremely flammable and can be explosive 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.
the carburetor, and drain the fuel into a suitable
• Remove
container.
• Remove the float bowl.
FUEL SYSTEM 2-9
Carburetor
• Drive out the pivot pin [A] and remove the float [B].
the tang [A] on the float arm very slightly to change
• Bend
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
NOTE
○Float height [A] is the distance from the float bowl mating surface [B] of the carburetor body (with the gasket
removed) to the top of the float [C]. Measure the height
with the carburetor upside down.
○Do not push the needle rod [D] in during the float height
measurement.
the carburetor, and recheck the fuel level.
• Assemble
If the fuel level cannot be adjusted by this method, the
float or the float valve is damaged.
Carburetor Removal
WARNING
Gasoline is extremely flammable and can be explosive 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.
the fuel tap to the OFF position and pull the fuel hose
• Turn
off the tap.
in the upper and lower throttle cable adjusters to
• Screw
give the cable plenty of play (see Throttle Cable Adjust-
•
ment).
Loosen the carburetor clamp screws [A] and remove the
carburetor from the end of the air cleaner duct, and then
pull it out of the carburetor holder from the vehicle left side.
2-10 FUEL SYSTEM
Carburetor
the carburetor cap [A], and pull out the throttle
• Unscrew
valve assembly [B].
CAUTION
If the throttle valve is left attached to the cable, wrap
it in a clean cloth to avoid damage.
removing the carburetor, push a clean, lint-free towel
• After
into the carburetor holder and the air cleaner duct to keep
dirt or other foreign material from entering.
WARNING
If dirt or dust is allowed to pass through into the
carburetor, the throttle may become stuck, possibly
causing an accident.
CAUTION
If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
Carburetor Installation
careful not to bend or otherwise damage the jet
• Being
needle, align the groove [A] in the throttle valve with the
guide pin [B] in the carburetor body.
○Check to see that the throttle valve goes all the way down
into the carburetor body, and slides smoothly.
• Fit the ridge [A] into the notch [B] on the carburetor holder.
the carburetor clamp screws on the air cleaner
• Tighten
duct and carburetor holder securely.
the air vent hose and overflow hose through the
• Route
clamp on the crankcase (see Cable, Wire and Hose Routing Section in the General Information chapter).
CAUTION
Always keep the hoses free from obstruction, and
make sure they do not get pinched by the chain or
shock absorber.
FUEL SYSTEM 2-11
Carburetor
the fuel tap to the ON position, and check for fuel
• Turn
leakage from the carburetor.
WARNING
Fuel spilled from the carburetor is hazardous.
the following items if necessary:
• Adjust
Throttle Cable (see this chapter)
Idle Speed (see this chapter)
Fuel Inspection
WARNING
Gasoline is extremely flammable and can be explosive 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.
the fuel tap to the OFF position.
• Turn
the carburetor.
• Remove
Place
a
suitable
beneath the carburetor.
• Remove the draincontainer
plug
[A]
the bottom of the float
• bowl and check for water or from
dirt in the fuel.
•
•
If any water or dirt comes out, clean the carburetor, fuel
tap and fuel tank (see this chapter).
Install the drain plug on the float bowl, and tighten it securely.
Install the carburetor.
Carburetor Disassembly
WARNING
Gasoline is extremely flammable and can be explosive 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.
the carburetor (see this chapter).
• Remove
Disassemble
the throttle valve assembly as follows.
•○Hold the throttle
valve return spring [A] compressed, take
out the retainer [B], and free the throttle cable by sliding it
through the slot.
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].
the carburetor body.
• Disassemble
Choke Plunger Assembly [A] (unscrew)
Idle Adjusting Screw, Spring and O-ring [B] (unscrew)
Air Screw and Spring [C] (unscrew)
the carburetor body bottom end.
• Disassemble
Float Bowl [A]
Gasket [B]
Pivot Pin [C] (drive out)
Float [D]
Float Valve [E]
Needle Jet [F]
Plastic Holder [G]
Pilot Jet [H]
Main Jet [I]
Carburetor Assembly
• Clean the disassembled parts (see this chapter).
CAUTION
Do not overtighten the jets. They could be damaged
requiring replacement.
the float bowl gasket with a new one if it is dete• Replace
riorated or damaged.
• Be sure to install the retainer [A].
Carburetor Cleaning
WARNING
Clean the carburetor in a well-ventilated area, and
take care that there is no spark or flame anywhere
near the working area; this includes any appliance
with a pilot light. Because of the danger of highly
flammable liquids, do not use gasoline or low flash
-point solvent to clean the carburetor.
sure the fuel tap is in the OFF position.
• Make
Remove
carburetor.
• Drain thethe
fuel
in the carburetor.
• Disassemble the
carburetor.
•
FUEL SYSTEM 2-13
Carburetor
CAUTION
Do not use compressed air on an assembled carburetor, the float may be deformed by the pressure.
Remove as many rubber or plastic parts from the
carburetor as possible before cleaning the carburetor with a cleaning solution. This will prevent
damage or deterioration of the parts. Do not use
a strong carburetor cleaning solution which could
attack the plastic parts; instead, use a mild high
flash-point cleaning solution safe for plastic parts.
Do not use wire or any other hard instrument to
clean carburetor parts, especially jets, as they may
be damaged.
all the metal parts in a carburetor cleaning solu• Immerse
tion.
the parts in water.
• Rinse
After
the
parts are cleaned, dry them with compressed air.
• Blow through
the air and fuel passages with compressed
• air.
• Assemble the carburetor, and install it on the motorcycle.
Carburetor Inspection
WARNING
Gasoline is extremely flammable and can be explosive 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.
the carburetor.
• Remove
Before
disassembling
the carburetor, check the fuel level
• (see Fuel Level Inspection).
•
•
•
If the fuel level is incorrect, inspect the rest of the carburetor before correcting it.
Pull the carburetor cable to check that the throttle valve
[A] moves smoothly and returns by spring pressure.
If the throttle valve does not move smoothly. Replace the
carburetor.
Disassemble the carburetor.
Clean the carburetor.
2-14 FUEL SYSTEM
Carburetor
the tapered portion [A] of the pilot screw [B] for
• Check
wear or damage.
If the pilot screw is worn or damaged on the tapered portion , it will prevent the engine from idling smoothly. Replace it.
the float valve needle [B].
• Remove
Check
the
tip [A] for wear.
• If the needleplastic
is worn as shown [C], replace the valve nee-
•
dle.
Push the rod [D] in the valve needle, then push and release [E] it.
If the rod does not come out fully by spring tension, replace the valve needle.
the slow jet.
• Remove
Check
the
slow jet for any damage.
• If the slow jet
is damaged, replace it with a new one.
Remove
the
throttle
and jet needle.
• Inspect the outside ofvalve
the
throttle
valve for scratches and
• abnormal wear.
•
•
•
If it is badly scratched or worn, replace the throttle valve.
Inspect the inside of the carburetor body for these same
faults.
If it is badly scratched or worn, replace the entire carburetor.
Check the jet needle for wear.
A worn jet needle should be replaced.
Clean the fuel and air passages with a high flash-point
solvent and compressed air.
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 Housing Installation
is the reverse of the removal.
• Installation
Tighten
the
rear frame mounting bolts.
•
Torque - Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
Air Cleaner Housing Plate Nuts: 3.0 N·m (0.31
kgf·m, 27 in·lb)
Air Cleaner Housing Mounting Bolts: 8.8 N·m
(0.90 kgf·m, 78 in·lb)
Element Removal
the seat.
• Remove
the wing bolt [A] and pull out the element [B].
• Remove
Stuff
a
clean,
lint-free towel into the carburetor so no dirt
• is allowed to enter
the carburetor.
Wipe
out
the
inside
of the air cleaner housing with a clean
• damp towel.
CAUTION
Check inside of the inlet tract and carburetor for
dirt. If dirt is present, clean the intake tract and carburetor thoroughly. You may also need to replace
the element and seal the housing and inlet tract.
Element Installation
installing the element, coat the lip of the element
• When
with a thick layer of all purpose grease [A] to assure a
complete seal against the air cleaner element base. Also,
coat the base where the lip of the element fits.
2-16 FUEL SYSTEM
Air Cleaner
the element [A].
•○Install
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.
○Since repeated cleaning opens the pores of the element, replace it with a new one in accordance with the
Periodic Maintenance Chart. Also, if there is a break in
the element material or any other damage to the element, replace the element with a new one.
WARNING
Clean the element 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. Because of the danger of highly
flammable liquids, do not use gasoline or a low
flash-point solvent to clean the element.
the air cleaner element, and separate the ele• Remove
ment [A] from the frame [B].
the element in a bath of a high flash-point solvent
• Clean
using a soft bristle brush. Squeeze it dry in a clean towel.
•
•
•
•
•
Do not wring the element or blow it dry; the element can
be damaged.
Check all the parts of the element for visible damage.
If any of the parts of the element are damaged, replace
them.
After cleaning, saturate the element with a high-quality
foam-air-filter oil, squeeze out the excess, then wrap it in
a clean rag and squeeze it as dry as possible. Be careful
not to tear the sponge filter.
Assemble the element.
Remove the towel from the carburetor.
Install the element.
FUEL SYSTEM 2-17
Fuel Tank
Fuel Tank Removal
WARNING
Gasoline is extremely flammable and can be explosive 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
Turn the fuel tap to the OFF position.
Pull the fuel hose off the fuel tap.
Remove the fuel tank mounting bolt [A] and band [B].
Remove the fuel tank [C].
Drain the fuel tank.
Fuel Tank Installation
the rubber damper [A] on the frame.
• Check
If the damper is damaged or deteriorated, replace it.
the rubber damper [A] noting its installing direction
• Install
as shown.
sure the fuel hose is clamped to the fuel tap to prevent
• Be
leaks.
the fuel tank breather hose outlet end into the num• Insert
ber plate hole.
Fuel Tap Removal
the fuel tank and drain it.
• Remove
Remove
• [B]. the mounting bolts [A] and take out the fuel tap
Fuel Tap Installation
sure the O-ring is in good condition to prevent leaks.
• Be
Be
sure
to clamp the fuel hose to the tap to prevent leaks.
•
2-18 FUEL SYSTEM
Fuel Tank
Fuel Tap Inspection
the fuel tap.
• Remove
the fuel tap filter screen [A] for any breaks or dete• Check
rioration.
If the fuel tap screen have any breaks or is deteriorated, it
may allow dirt to reach the carburetor, causing poor running. Replace the fuel tap.
If the fuel tap leaks, or allows fuel to flow when it is at OFF
position, replace the damaged O-ring [B].
Fuel Tank and Tap Cleaning
WARNING
Clean the tank in a well-ventilated area, and take
care that there is no sparks or flame anywhere near
the working area. Because of the danger of highly
flammable liquids, do not use gasoline or low flash
-point solvent to clean the tank.
the fuel tank and drain it.
• Remove
some high flash-point solvent into the fuel tank and
• Pour
shake the tank to remove dirt and fuel deposits.
the solvent out of the tank.
• Pour
Remove
from the tank by taking out the bolts.
• Clean thethefuelfueltaptapfilter
screen in a high flash-point sol• vent.
high flash-point solvent through the tap in all lever
• Pour
positions.
the tank and tap with compressed air.
• Dry
Install
tap in the tank.
• Install the
the
fuel tank.
•
FUEL SYSTEM 2-19
Reed Valve
Reed Valve Removal
the carburetor holder mounting bolts and carbu• Remove
retor holder [A].
• Remove the reed valve [B] out of the cylinder.
Reed Valve Installation
the reed or stop are replaced, install the reed [A]
• When
and stop [B] onto the reed valve holder [C], aligning the
chamfered corner [D] of the reed with that of the reed stop.
Torque - Read Valve Screws: 9.8 N·m (1 kgf·m, 87 in·lb)
the reed valve [A] and carburetor holder [B].
•○Install
Be sure the clamp [C] is in horizontal and torque the carburetor holder mounting bolts [D].
Torque - Carburetor Holder Mounting Bolts: 8.8 N·m (0.90
kgf·m, 78 in·lb)
Reed Valve Inspection
the reeds for cracks, folds, or other visible dam• Inspect
age.
•
If there is any doubt as to the condition of a reed, replace
the reed valve part with a new one.
If a reed becomes wavy, replace the valve part with a new
one even if its warp is less than the service limit.
Measure the clearance between the reed [A] and holder
[B], and check the reed warp as shown.
If any one of the clearance measurements exceeds the
service limit, replace the valve part with a new one.
Reed Warp
Service Limit: 0.5 mm
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 fraying, cracks [B] or bulges
[C] are noticed.
Check that the hoses are securely connected and clamps
are tightened correctly.
When installing, route the hoses according to Cable, Wire
and Hose Routing section in the General Information
chapter.
When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the fuel hoses with a
minimum of bending so that the fuel flow will not be obstructed.
Replace the hose if it has been sharply bent or kinked.
COOLING SYSTEM 3-1
Cooling System
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Coolant ...................................................................................................................................
Coolant Level Inspection...................................................................................................
Coolant Deterioration Inspection.......................................................................................
Coolant Draining ...............................................................................................................
Coolant Filling ...................................................................................................................
Air Bleeding.......................................................................................................................
Cooling System Pressure Testing .....................................................................................
Cooling System Flushing ..................................................................................................
Disassembly and Assembly Precautions................................................................................
Water Pump............................................................................................................................
Water Pump Cover Removal ............................................................................................
Water Pump Cover Installation ........................................................................................
Impeller Removal ..............................................................................................................
Impeller Installation ...........................................................................................................
Impeller Inspection............................................................................................................
Water Pump Shaft Removal .............................................................................................
Water Pump Shaft Installation ..........................................................................................
Oil Seal Removal ..............................................................................................................
Oil Seal Installation ...........................................................................................................
Radiator ..................................................................................................................................
Radiator Removal .............................................................................................................
Radiator Installation ..........................................................................................................
Radiator Inspection ...........................................................................................................
Cap Inspection ..................................................................................................................
Filler Neck Inspection........................................................................................................
Water Hoses, Breather Hose Inspection...........................................................................
Water Hoses, Breather Hose Installation ..........................................................................
3-2
3-3
3-4
3-4
3-4
3-5
3-5
3-6
3-6
3-7
3-8
3-9
3-9
3-9
3-9
3-9
3-9
3-10
3-10
3-10
3-10
3-12
3-12
3-12
3-12
3-13
3-13
3-13
3-13
3
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 (0.85 kgf·m, 73 in·lb)
T3: 5.9 N·m (0.60 kgf·m, 52 in·lb)
T4: 1.5 N·m (0.15 kgf·m, 13 in·lb)
G: Apply grease.
M: Apply molybdenum disulfide grease.
COOLING SYSTEM 3-3
Specifications
Item
Coolant
Type
Color
Mixed ratio
Total amount
Radiator
Cap relief pressure
Standard
Permanent type antifreeze for aluminum engines and radiators
Green
Soft water 50%, coolant 50%
0.4 L
108 ∼ 137 kPa (1.1 ∼ 1.4 kgf/cm², 16 ∼ 20 psi)
Special Tools - Bearing Driver Set: 57001-1129
Outside Circlip Pliers: 57001-144
3-4 COOLING SYSTEM
Coolant
Check the coolant level each day before riding the motorcycle, and replenish coolant if the level is low. Change the
coolant in accordance with the Periodic Maintenance Chart
(see General Information chapter).
WARNING
To avoid burns, do not remove the radiator cap
or try to inspect the coolant level or change the
coolant when the engine is still hot. Wait until it
cools down.
Coolant Level Inspection
NOTE
○Check the level when the engine is cold (room or ambient temperature).
the motorcycle so that it is perpendicular to the
• Situate
ground.
• Remove the radiator cap [A].
NOTE
○Remove the radiator cap in two steps.
First turn the
cap counterclockwise to the first stop and wait there for
a few seconds. Then push down and turn it further in
the same direction and remove the cap.
the coolant level. The coolant level [A] should be
• Check
at the bottom of the filler neck [B].
If the coolant level is low, add coolant through the filler
opening to the bottom of the filler neck. Install the cap.
Recommended Coolant:
Permanent type of antifreeze (soft water and ethylene
glycol plus corrosion and rust inhibitor chemicals for
aluminum engines and radiators)
Water and Coolant Mixture Ratio:
1 : 1 (water 50%, Coolant 50%)
Total amount: 0.4 L
Coolant Deterioration Inspection
inspect the coolant.
• Visually
If whitish cotton-like wafts are observed, aluminum parts
in the cooling system are corroded. If the coolant is
brown, iron or steel parts are rusting. In either case, flush
the cooling system.
If the coolant gives off an abnormal smell, check for a
cooling system leak. It may be caused by exhaust gas
leaking into the cooling system.
COOLING SYSTEM 3-5
Coolant
Coolant Draining
The coolant should be changed periodically to ensure
long engine life.
WARNING
To avoid burns, do not remove the radiator cap or
try to change the coolant when the engine is still
hot. Wait until it cools down.
Coolant on tires will make them slippery and can
cause an accident and injury. Immediately wipe up
or wash away any coolant that spills on the frame,
engine or other painted parts. Since coolant is
harmful to the human body, do not use for drinking.
• Remove the radiator cap.
NOTE
○Remove the radiator cap in two steps.
First turn the
cap counterclockwise to the first stop and wait there for
a few seconds. Then push down and turn it further in
the same direction and remove the cap.
a container under the coolant drain plug [A], and
• Place
drain the coolant from the radiator and engine by remov-
•
ing the drain plug on the water pump cover. Immediately
wipe or wash out any coolant that spills on the frame, engine, or wheel.
Inspect the old coolant for visual evidence of corrosion
and abnormal smell (see Coolant Deterioration Inspection).
Coolant Filling
CAUTION
Use coolant containing corrosion inhibitors made
specifically for aluminum engines and radiators in
accordance with the instruction of the manufacturer. Soft or distilled water must be used with the
antifreeze (see below for antifreeze) in the cooling
system. If hard water is used in the system, it
causes scale accumulation in the water passages,
and considerably reduces the efficiency of the
cooling system.
Recommended Coolant
Type:
Permanent type antifreeze (soft
water and ethylene glycol plus
corrosion and rust inhibitor
chemicals for aluminum engines
and radiators)
Color:
Green
Mixed Ratio:
Soft water 50%, Coolant 50%
Freezing Point:
–35°C (–31°F)
Total Amount:
0.4 L
3-6 COOLING SYSTEM
Coolant
the coolant drain plug.
•○Install
Replace the gasket with a new one.
Torque - Coolant Drain Plug (Water Pump): 8.8 N·m (0.90
kgf·m, 78 in·lb)
the radiator up to the bottom of the radiator filler neck
• Fill
[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 in two steps. First turn the cap clockwise to the
first stop. Then push down on it and turn it the rest of
the way.
• Check the cooling system for leaks.
Air Bleeding
the air from the cooling system as follows.
•○Bleed
Loosen the air bleeder bolt [A] on the cylinder head until
the coolant begins to flow out the air bleeder bolt hole (that
is, until all the remaining air has been forced out).
○Tighten the air bleeder bolt.
Torque - Air Bleeder Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
○Start the engine with the radiator cap removed and run it
until no more air bubbles [A] can be seen in the coolant.
○Tap the cooling hoses to force any air bubbles caught
inside.
○Stop the engine and add coolant up to the filler neck.
Check the cooling system for leaks.
Install the radiator cap.
○The radiator cap must be installed in two steps. First turn
the cap clockwise to the first stop. Then push down on it
and turn it the rest of the way.
•
•
Cooling System Pressure Testing
CAUTION
During pressure testing, do not exceed the pressure for which the system is designed to work. The
maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi).
the radiator cap, and install a cooling system
• Remove
pressure tester [A] and adapter [B] on the radiator filler
neck [C].
○Wet
NOTE
the adapter cap sealing surfaces with water or
coolant to prevent pressure leaks.
COOLING SYSTEM 3-7
Coolant
up pressure in the system carefully until the pres• Build
sure reaches 123 kPa (1.25 kgf/cm², 18 psi).
the gauge for at least 6 seconds. If the pressure
• Watch
holds steady, the cooling system is all right.
the pressure tester, replenish the coolant, and
• Remove
install the radiator cap.
If the pressure drops and no external source is found,
check for internal leaks. Check the cylinder head gasket
for leaks.
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 cooling system. If this accumulation is not removed, it will clog
up the water passages and considerably reduce the efficiency of the cooling system.
Drain the cooling system.
Fill the cooling system with fresh water mixed with a flushing compound.
•
•
CAUTION
Avoid the use of a flushing compound which is
harmful to the aluminum engine and radiator.
Carefully follow the instructions supplied by the
manufacturer of the cleaning product.
up the engine, and run it at normal operating tem• Warm
perature for about ten minutes.
the engine, and drain the cooling system after the
• Stop
coolant cools down.
the system with fresh water.
• Fill
Warm
the engine and drain the system after the
• coolantupcools
down.
Repeat
the
previous
steps once more.
• Fill the system with atwo
type coolant, and bleed
• the air from the systempermanent
(see Air Bleeding).
3-8 COOLING SYSTEM
Disassembly and Assembly Precautions
to disassembly of cooling system parts (radiator,
• Prior
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.
COOLING SYSTEM 3-9
Water Pump
Water Pump Cover Removal
the coolant (see Coolant Draining).
• Drain
the water hose clamps [A], and disconnect the
• Loosen
water hoses on the water pump cover [B].
the cover bolts [C], and remove the water pump
• Unscrew
cover.
Water Pump Cover Installation
the pump cover gasket with a new one.
• Replace
• Tighten the water pump cover bolts and clamps.
Torque - Water Pump Cover Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
the cooling system (see Coolant Filling).
• Fill
Bleed
the air from the cooling system.
•
Impeller Removal
the coolant (see Coolant Draining).
• Drain
Remove
bolts and take out the water pump
• cover fromthethecover
right engine cover with the water hoses
•
attached.
Remove the water pump impeller bolt [A], and take out
the impeller [B] and washer.
Impeller Installation
• Tighten the water pump impeller bolt.
Torque - Water Pump Impeller Bolt: 8.3 N·m (0.85 kgf·m, 73
in·lb)
Impeller Inspection
check the impeller [A].
• Visually
If the surface is corroded, or if the blades [B] are damaged, replace the impeller.
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).
Pull out the water pump shaft [C] toward inside of the right
engine cover.
•
•
Water Pump Shaft Installation
prevent the oil seal lips from peeling, apply a molybde• To
num disulfide grease [A] to the water pump shaft [B] and
insert it into the oil seals [C] from the inside of the right
engine cover [D].
CAUTION
Be sure to apply a molybdenum disulfide grease
to the water pump shaft when installing. If it is installed dry, the seals may wear excessively.
• Replace the circlip for the primary gear with a new one.
Special Tool - Outside Circlip Pliers: 57001-144
the impeller and check to see that the impeller turn
• Instal
freely.
Oil Seal Removal
• Remove:
Impeller (see this chapter)
•
Right Engine Cover (see Engine Right Side chapter)
To remove the oil seals. Insert a metal rod into the right
engine cover from the opposite side of the impeller, and
tap evenly around the bottom of the seal.
[A] Metal Rod
[B] Oil Seals
[C] Tap
[D] Ball Bearing
Oil Seal Installation
CAUTION
If the oil seal or ball bearing is removed, replace all
of them with new ones at the same time
• Be sure to replace the oil seals.
COOLING SYSTEM 3-11
Water Pump
the ball bearing [A] into the hole until the bearing is
• Press
bottomed against the step [B].
Special Tools - Bearing Driver Set: 57001-1129
plenty of high temperature grease to the oil seal lips
• Apply
[D].
the oil seal (thick) so that dual lips side face outward
• Set
and set the oil seal (thin) so that a lip faces outward as
•
shown.
Press the oil seals [E] into the hole until the oil seal is
bottomed against the ball bearing or the seal.
Special Tools - Bearing Driver Set: 57001-1129 [C]
○The end of the oil seal must be 0.5 ± 0.2 mm [F] lower
than the end of the right engine cover end [G].
○Be sure the inner race of the ball bearing [A] turns
smoothly.
3-12 COOLING SYSTEM
Radiator
Radiator Removal
the coolant (see Coolant Draining).
• Drain
• Remove:
Left Shroud [A]
Water Hose [B]
Radiator Mounting Bolts [C]
Radiator Screen [D]
Breather Hose
Radiator [E]
Radiator Installation
installation is the reverse of removal.
• Radiator
Route
the
water and breather hoses correctly.
•
Torque - Radiator Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
Shroud Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
Radiator Inspection
the radiator core.
• Check
If there are obstructions to air flow, remove them.
If the corrugated fins are deformed, carefully straighten
them with the thin blade of a screwdriver [A].
CAUTION
Do not tear the radiator tubes while straightening
the fins.
If the air passages of the radiator core are blocked more
than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.
CAUTION
When cleaning the radiator with a steam cleaner, be
careful of the following to prevent radiator damage.
Keep the steam gun [C] away more than 0.5 m [B]
from the radiator core. Hold the steam gun perpendicular to the core surface. Run the steam gun following the core fin direction [A].
COOLING SYSTEM 3-13
Radiator
Cap Inspection
the condition of the valve spring [B], and the top
• Check
and bottom valve seals [A] of the radiator cap.
If any one of them shows visible damage, replace the cap.
the top and bottom valve seals with water or coolant
• Wet
to prevent pressure leaks.
the cap [A] on a cooling system pressure tester [B].
• Install
Watching
the pressure gauge, slowly pump the pressure
• tester to build
up the pressure. The gauge hand must
remain within the relief pressure range in the table below
at least 6 seconds. Continue to pump the tester until the
relief valve opens, indicated by the gauge hand flicking
downward. The relief valve must open within the specified
range.
Radiator Cap Relief Pressure:
108 ∼ 137 kPa (1.1 ∼ 1.4 kgf/cm², 16 ∼ 20
Standard:
psi)
If the cap cannot hold the pressure, or if the relief pressure
is too high or too low, replace the cap with a new one.
Filler Neck Inspection
the radiator filler neck for signs of damage.
• Check
the condition of the top and bottom sealing seats
• Check
[A] in the filler neck. They must be smooth and clean for
the radiator cap to function properly.
Water Hoses, Breather Hose Inspection
accordance with the Periodic Maintenance Chart,
• Invisually
inspect the hoses [A] for signs of deterioration.
•
Squeeze the hose. A hose should not be hard and brittle,
nor should it be soft or swollen.
Replace any damaged hose.
Water Hoses, Breather Hose Installation
the water hoses or breather hose being careful
• Install
to follow the performed bends (see General Information
•
chapter). Avoid sharp bending, kinking, flattening, or
twisting.
Tighten the hose clamps securely.
ENGINE TOP END 4-1
Engine Top End
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Cylinder Head.........................................................................................................................
Cylinder Compression Measurement................................................................................
Cylinder Head Removal ....................................................................................................
Cylinder Head Installation .................................................................................................
Cylinder Head Warp Inspection ........................................................................................
Cylinder ..................................................................................................................................
Cylinder Removal..............................................................................................................
Cylinder Installation...........................................................................................................
Piston Removal.................................................................................................................
Piston Installation..............................................................................................................
Cylinder Wear Inspection..................................................................................................
Piston Diameter Measurement .........................................................................................
Piston/Cylinder Clearance Inspection ...............................................................................
Piston Ring, Piston Ring Groove Inspection .....................................................................
Piston Ring End Gap Inspection .......................................................................................
Piston, Piston Pin, Connecting Rod Wear Inspection .......................................................
Muffler (Expansion Chamber).................................................................................................
Muffler Removal................................................................................................................
Muffler Installation.............................................................................................................
Muffler Baffle Replacement...............................................................................................
4-2
4-3
4-4
4-4
4-4
4-5
4-5
4-6
4-6
4-6
4-6
4-7
4-8
4-8
4-8
4-9
4-9
4-10
4-11
4-11
4-11
4-11
4
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·lb)
T3: 26 N·m (2.6 kgf·m, 19 ft·lb)
T4: 8.8 N·m (0.90 kgf·m, 78 in·lb)
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
O: Apply 2-stroke engine oil.
SS: Apply silicone sealant.
ENGINE TOP END 4-3
Specifications
Item
Cylinder Head
Cylinder Compression
Cylinder head warp
Cylinder, Piston
Cylinder Inside Diameter (15 mm below
from the Cylinder Top End)
Piston Diameter
Piston/Cylinder Clearance
Piston Ring/Groove Clearance (Top,
Second)
Piston Ring Groove Width (Top,
Second)
Piston Ring Thickness (Top, Second)
Piston Ring End Gap (Top, Second)
Piston Pin Diameter
Piston Pin Hole Diameter
Small End Inside Diameter
Standard
Service Limit
(Usable range)
755 ∼ 1 177 kPa (7.70 ∼ 12.0 kgf/cm²,
109 ∼ 171 psi)
–––
– – –
0.03 mm
44.500 ∼ 44.515 mm
44.64 mm
44.453 ∼ 44.468 mm
0.042 ∼ 0.052 mm
0.02 ∼0.06 mm
44.30 mm
– – –
0.16 mm
1.01 ∼ 1.03 mm
0.97 ∼ 0.99 mm
0.15 ∼ 0.35 mm
11.995 ∼ 12.000 mm
12.001 ∼ 12.011 mm
16.002 ∼ 16.013 mm
Special Tool - Piston Pin Puller Assembly: 57001-910
1.11 mm
0.90 mm
0.65 mm
11.96 mm
12.08 mm
16.05 mm
4-4 ENGINE TOP END
Cylinder Head
Cylinder Compression Measurement
the engine.
• Start
warm up the engine so that the engine oil be• Thoroughly
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, and screw a compression gauge
firmly into the spark plug hole.
NOTE
○Use a compression gauge commercially available.
It’s
impossible to install as the frame will interfere with the
operation if using KAWASAKI special tools (PN: 57001
-221 & 57001-1159).
the throttle fully open, turn the engine over sharply
• With
with the kickstarter several times until the compression
gauge stops rising the compression is the highest reading
obtainable.
Cylinder Compression
Usable Range:
755 ∼ 1 177 kPa (7.70 ∼ 12.0
kgf/cm², 109 ∼ 171 psi)
If cylinder compression is higher than the usable range,
check the following:
1. Carbon build up on the piston head and cylinder head
- clean off any carbon on the piston head and cylinder
head.
2. Cylinder head gasket, cylinder base gasket - use only
the proper gaskets for the cylinder head and base. The
use of gasket of the incorrect thickness will change the
compression.
If cylinder compression is lower than the usable range,
check the following:
1. Piston/cylinder clearance, piston seizure
2. Gas leakage around the cylinder head - replace the
damaged gasket and check the cylinder head for warping.
3. Piston ring, piston ring groove, piston ring groove clearance
Cylinder Head Removal
the coolant (see Cooling System chapter).
• Drain
• Remove:
Shrouds
•
Side Covers
Fuel Tank (see Fuel System chapter)
Cooling Hose at Cylinder Head
Spark Plug
Remove the cylinder head nuts [A], and take off the cylinder head [B] and gasket [C].
ENGINE TOP END 4-5
Cylinder Head
Cylinder Head Installation
the head gasket with a new one.
• Replace
out any carbon and clean the head with a high
• Scrape
flash-point solvent.
for a crust of minerals and rust in the head water
• Check
jacket, and remove them if necessary.
a new cylinder head gasket [A] so that its “UP” mark
• Install
[B] faces toward exhaust side [C] and can be read as
•
•
“UP”.
Install the cylinder head [D], noting its direction as shown.
Tighten the head nuts diagonally.
Torque - Cylinder Head Nuts: 25 N·m (2.5 kgf·m, 18 ft·lb)
• Tighten the spark plug.
Torque - Spark plug: 26 N·m (2.6 kgf·m, 19 ft·lb)
Cylinder Head Warp Inspection
a straightedge [A] across the lower surface of the
• Lay
head at several different points, and measure warp by
inserting a thickness gauge [B] between the straightedge
and the head.
If warp exceeds the service limit, repair the mating surface. Replace the cylinder head if the mating surface is
badly damaged.
Cylinder Head Warp
0.03 mm
Standard:
4-6 ENGINE TOP END
Cylinder
Cylinder Removal
the coolant (see Cooling System chapter).
• Drain
• 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 [B], and remove the cylinder base gasket. If necessary, tap lightly around the base of the cylinder with a plastic mallet, taking care not to damage the
cylinder.
Cylinder Installation
any carbon out of the exhaust port.
• Scrape
Check
on
of minerals and rust in the cylinder water
• jacket, anda crust
remove them if necessary.
the cylinder base gasket with a new one.
• Replace
Apply
engine
• cylinder bore. oil to the piston surface, piston rings and
to see that the pin [A] in each piston ring groove
• Check
is between the ends of the piston ring, and fit the base of
•
the cylinder over each ring, pressing in on opposite sides
of the ring as necessary. Be certain that the rings do not
slip out of position.
Tighten the cylinder nuts diagonally.
Torque - Cylinder Nuts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Piston Removal
the cylinder.
• Remove
Stuff
a
clean
into the crankcase opening around the
• connecting rodcloth
so that no parts will fall into the crankcase.
one of the piston pin snap rings with needle nose
• Remove
pliers.
the piston by pushing the piston pin out the side
• Remove
from which the snap ring was removed. Use a piston pin
puller assembly [A], if the pin is tight.
Special Tools - Piston Pin Puller Assembly: 57001-910
the piston ring(s).
•○Remove
Carefully spread the ring [A] opening with your thumbs
and then push up on the opposite side of the ring to remove it.
ENGINE TOP END 4-7
Cylinder
Piston Installation
a clean cloth into the crankcase opening around the
• Stuff
connecting rod so that no parts will fall into the crankcase.
off any carbon of the piston, then lightly polish the
• Scrape
piston with fine emery cloth.
carbon and dirt out of the piston ring groove using
• Clean
a suitable tool.
CAUTION
Carbon particles can be very abrasive to piston
ring. Don’t allow such particles to fall onto the
cylinder walls.
installing the piston ring on the piston, note the fol• When
lowing:
○First fit one end of the piston ring against the pin in the
ring groove, spread the ring opening with the other hand
and then slip the ring into the groove.
○The top ring have a “1N” mark [A] on its upper surface.
○The second ring have a “2N” mark [B] on its upper surface.
○Install the ring so that the pin [A] in the piston ring groove
is between the ends of the piston ring.
2-stroke engine oil to the connecting rod needle
• Apply
bearing and the piston pin.
the piston [A] so that the “IN” marked side [B] faces
• Install
the back (intake) side of the engine.
installing a piston pin snap ring [A], compress it only
• When
enough to install it and no more.
CAUTION
Do not reuse snap rings, as removal weakens and
deforms them. They could fall out and score the
cylinder wall.
a new piston pin snap ring into the side of the piston so
• Fit
that the ring opening [B] does not coincide with the notch
[C] in the edge of the piston pin hole.
4-8 ENGINE TOP END
Cylinder
Cylinder Wear Inspection
NOTE
○Measure the cylinder inside diameter when the cylinder
is cold (room or ambient temperature).
Inspect the inside of the cylinder for scratches
• Visually
and abnormal wear.
•
If the cylinder is damaged or badly worn, replace it with a
new one.
Since there is a difference in cylinder wear in different directions, take a side-to-side and a front-to back measurement shown in the figure.
If any of the cylinder inside diameter measurements exceeds the service limit, the cylinder must be replaced with
a new one since the ELECTRO FUSION cylinder cannot
be bored or honed.
Cylinder Inside Diameter
44.500 ∼ 44.515 mm, and less than
Standard:
0.01 mm difference between any two
measurements.
Service Limit:
44.64 mm, or more than 0.05
mm difference between any two
measurements.
[A]:
15 mm
Piston Diameter Measurement
the outside diameter [B] of the piston 6.0 mm
• Measure
[A] up from the bottom of the piston at a right angle to the
direction of the piston pin.
If the measurement is under the service limit, replace the
piston.
Piston Diameter
Standard:
44.453 ∼ 44.468 mm
Service Limit:
44.30 mm
[A]:
6.0 mm
Piston/Cylinder Clearance Inspection
The piston-to-cylinder clearance is measured whenever a
piston or cylinder is replaced with a new one. The standard
piston-to-cylinder clearance must be adhered to whenever
the cylinder is replaced.
If only a piston is replaced, the clearance may exceed the
standard slightly. But it must not be less than the minimum,
in order to avoid piston seizure.
The most accurate way to find the piston clearance is
by making separate piston and cylinder diameter measurements and then computing the difference between the two
values. Measure the piston diameter as just described, and
measure the cylinder diameter at the very bottom of the
cylinder.
Piston/Cylinder Clearance
0.042 ∼ 0.052 mm
Standard:
ENGINE TOP END 4-9
Cylinder
Piston Ring, Piston Ring Groove Inspection
inspect
• Visually
grooves.
•
•
•
the piston rings and the piston ring
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 by inspecting the ring seating.
The rings should fit perfectly parallel to the groove surfaces. If not, the piston must be replaced.
With the piston ring in its groove, make several measurements with a thickness gauge [A] to determine piston
ring/groove clearance.
If the clearance exceeds the service limit, measure the
thickness of the piston ring
If the ring has worn down to less than the service limit,
replace the ring; if the groove width exceeds the service
limit, replace the piston.
Piston Ring/Groove Clearance (Top, Second)
0.02 ∼ 0.06 mm
Standard:
Service Limit:
0.16 mm
Piston Ring Thickness (Top, Second)
0.97 ∼ 0.99 mm
Standard:
Service Limit:
0.90 mm
Piston Ring Groove Width (Top, Second)
1.01 ∼ 1.03 mm
Standard:
Service Limit:
1.11 mm
Piston Ring End Gap Inspection
the piston ring [A] inside the cylinder [B], using the
• Place
piston to locate the ring squarely in place.
it close to the bottom of the cylinder, where cylinder
• Set
wear is low.
the gap [C] between the ends of the ring with a
• Measure
thickness gauge.
If the gap is wider than the service limit, the ring is overworn and must be replaced.
Piston Ring End Gap (Top, Second)
0.15 ∼ 0.35 mm
Standard:
Service Limit:
0.65 mm
4-10 ENGINE TOP END
Cylinder
Piston, Piston Pin, Connecting Rod Wear Inspection
inspect the snap ring [A] still fitted in place.
• Visually
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 micrometer.
If the piston pin diameter is less than the service limit at
any point, replace the piston pin.
Using a cylinder gauge, measure the diameter of both of
piston pin holes [C] in the piston and the inside diameter
of the connecting rod small end.
If either piston pin hole diameter exceeds the service limit,
replace the piston.
If the connecting rod small end inside diameter exceeds
the service limit, replace the crankshaft assembly.
Check the needle bearing [D].
○The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, other damage.
•
•
•
If there is any doubt as to the condition of a needle bearing, replace the bearing and piston pin.
Piston Pin Diameter
11.995 ∼12.000 mm
Standard:
Service Limit:
11.96 mm
Piston Pin Hole Diameter
12.001 ∼ 12.011 mm
Standard:
Service Limit:
12.08 mm
Small End Inside Diameter
Standard:
16.002 ∼ 16.013 mm
Service Limit:
16.05 mm
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.
the springs [A] holding the exhaust pipe holding
• Remove
.
the expansion chamber damper mounting bolts
• Remove
[A], and pull off the expansion chamber to the forward.
• Remove the exhaust gasket.
Muffler Installation
any carbon out of the expansion chamber.
• Scrape
Check
the
O-rings for signs of damage.
• If necessary,exhaust
replace them with new ones.
the springs [A] holding the exhaust pipe so that their
• Install
fixed hooks [B] face the cylinder.
Torque - Muffler Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
Expansion Chamber Damper Mounting Bolt, Nut:
8.8 N·m (0.90 kgf·m, 78 in·lb)
Muffler Baffle Replacement
Replace the muffler baffle if exhaust noise becomes too
loud or the engine performance drops.
Remove the muffler pipe bolts [A], and pull the muffler
pipe [B] from the muffler body.
Remove the muffler.
•
•
4-12 ENGINE TOP END
Muffler (Expansion Chamber)
the inner pipe mounting bolts [A].
• Unscrew
Pull
the
inner
pipe [B] from the muffler body.
•
off the old muffler baffle, and install the new muffler
• Pull
baffle [A] into the muffler body.
silicone sealant to the circumference [B] of the inner
• Apply
pipe.
a non-permanent locking agent to the inner pipe
• Apply
mounting bolts.
• Install the muffler.
Torque - Inner Pipe Mounting Bolts: 5.9 N·m (0.6 kgf·m, 52
in·lb)
ENGINE RIGHT SIDE 5-1
Engine Right Side
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Clutch Cable ...........................................................................................................................
Clutch Lever Free Play Inspection ....................................................................................
Free Play Adjustment........................................................................................................
Clutch Cable Removal ......................................................................................................
Clutch Cable Installation ...................................................................................................
Clutch Cable Lubrication and Inspection ..........................................................................
Right Engine Cover ................................................................................................................
Right Engine Cover Removal............................................................................................
Engine Right Cover Installation.........................................................................................
Right Engine Cover Disassembly .....................................................................................
Right Engine Cover Assembly ..........................................................................................
Clutch .....................................................................................................................................
Clutch Removal.................................................................................................................
Clutch Installation..............................................................................................................
Friction and Steel Plates Wear, Damage Inspection.........................................................
Friction and Steel Plate Warp Inspection ..........................................................................
Spring Free Length Measurement ....................................................................................
Friction Plate/Clutch Housing Clearance Inspection.........................................................
Clutch Hub Spline Inspection............................................................................................
External Shift Mechanism.......................................................................................................
External Shift Mechanism Removal ..................................................................................
External Shift Mechanism Installation ...............................................................................
External Shift Mechanism Inspection................................................................................
Primary Gear ..........................................................................................................................
Primary Gear Removal .....................................................................................................
Primary Gear Installation ..................................................................................................
Primary Gear Removal (KX65A6F ∼)................................................................................
Primary Gear Installation (KX65A6F ∼).............................................................................
Kickstarter...............................................................................................................................
Kickshaft Removal ............................................................................................................
Kickshaft Installation .........................................................................................................
Kickstarter Assembly Disassembly/Assembly ..................................................................
Idle Gear Removal ............................................................................................................
Idle Gear Installation .........................................................................................................
5-2
5-4
5-5
5-5
5-5
5-5
5-6
5-6
5-7
5-7
5-7
5-9
5-9
5-10
5-10
5-10
5-11
5-11
5-12
5-12
5-12
5-13
5-13
5-13
5-13
5-14
5-14
5-14
5-14
5-14
5-16
5-16
5-16
5-16
5-16
5-16
5
5-2 ENGINE RIGHT SIDE
Exploded View
ENGINE RIGHT SIDE 5-3
Exploded View
1. Clutch Lever
2. Clutch Cable
3. Release Lever Shaft
4. Clutch Pusher
5. Shim(s)
6. Spring Plate Pusher
7. Clutch Hub
8. Clutch Wheel
9. Friction Plate
10. Steel Plate
11. 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. Kick Shaft
20. KX65-A1 ∼ A6
T1: 8.8 N·m (0.90 kgf·m, 78 in·lb)
T2: 64 N·m (6.5 kgf·m, 47 ft·lb)
T3: 9.3 N·m (0.95 kgf·m, 82 in·lb)
T4: 5.2 N·m (0.53 kgf·m, 46 in·lb)
T5: 1.5 N·m (0.15 kgf·m, 13 in·lb)
T6: 49 N·m (5.0 kgf·m, 36 ft·lb)
T7: 12 N·m (1.2 kgf·m, 104 in·lb)
EO: Apply Engine oil.
G: Apply high temperature grease.
Lh: Left-hand Threads
M: Apply molybdenum disulfide grease.
O: Apply oil.
5-4 ENGINE RIGHT SIDE
Specifications
Item
Clutch
Lever Free Play
Friction Plate Thickness
Steel Plate Thickness
Friction Plate Warp
Steel Plate Warp
Clutch Spring Free Length
Friction Plate/Clutch Housing Clearance
Standard
2 ∼ 3 mm
3.1 ∼ 3.3 mm
1.47 ∼ 1.73 mm
Not more than 0.2 mm
Not more than 0.15 mm
28.1 mm
0.3 ∼ 0.6 mm
Special Tools - Flywheel & Pulley Holder: 57001-1605
Outside Circlip Pliers: 57001-144
Service Limit
– – –
2.9 mm
1.37 mm
0.3 mm
0.3 mm
26.7 mm
0.9 mm
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 accordance with the Periodic Maintenance Chart.
WARNING
To avoid a serious burn, never touch the hot engine
or exhaust chamber during clutch adjustment.
Clutch Lever Free Play Inspection
the clutch lever dust cover [A] out of place.
• Slide
that the clutch cable upper end is fully seated in
• Check
the adjuster [B].
that the clutch lever [C] has 2 ∼ 3 mm of play [D].
• Check
If it does not, adjust the lever play.
Free Play Adjustment
the clutch lever dust cover out of place.
• Slide
the knurled locknut [A].
• Loosen
Turn
the
[B] so that the clutch lever will have 2 ∼
• 3 mm of adjuster
play [C].
NOTE
○Be sure that the outer cable end at the clutch lever is
fully seated in the adjuster at the clutch lever, or it could
slip into the place later, creating enough cable play to
prevent clutch disengagement.
• Tighten the locknut.
it cannot be done, loosen the adjusting nuts [A] at the
• Ifbottom
of the clutch cable, and turn the nuts so that clutch
•
lever has 2 ∼ 3 mm of play.
After the adjustment is made, tighten the locknut, and
start the engine and check that the clutch does not slip
and that it release properly.
Clutch Cable Removal
the dust cover out of place.
• Slide
Loosen
adjusting nuts at the lower of the cable, and
• turn the the
adjusting nuts to give the cable plenty of play.
Loosen
knurled locknut [A] at the clutch lever, and
• screw inthe
the adjuster [B].
up the slots [C] in the clutch lever, knurled locknut,
• Line
and adjuster, and then free the cable from the clutch lever.
5-6 ENGINE RIGHT SIDE
Clutch Cable
the clutch inner cable tip from the clutch release
• Free
lever.
CAUTION
Do not remove the clutch release shaft unless it is
absolutely necessary. If removed, release shaft oil
seal must be replaced with a new one.
• Pull the clutch cable out of the frame.
Clutch Cable Installation
the clutch cable according to the Cable, Wire and
• Run
Hose Routing section of the General Information chapter.
• Adjust the clutch cable (see Free Play Adjustment).
Clutch Cable Lubrication and Inspection
the clutch cable [A] using the pressure cable
• Lubricate
lubber in accordance with the Periodic Maintenance
•
Chart.
With the cable disconnected at both ends, the cable
should move freely within the cable housing (see Appendix chapter).
ENGINE RIGHT SIDE 5-7
Right Engine Cover
Right Engine Cover Removal
the engine oil (see Engine Oil Change in the Engine
• Drain
Bottom End/Transmission chapter).
the coolant (see Coolant Draining in the Cooling
• Drain
System chapter).
• Remove:
Water Hose Lower Ends
•
•
Kick Pedal
Clutch Cable Lower End (see this chapter)
Brake Pedal
Water Pump Impeller (see Cooling System chapter)
Remove the right engine cover mounting bolts.
Turn the clutch release lever [A] toward the rear and remove the right engine cover [B].
Engine Right Cover Installation
molybdenum disulfide grease [A] to the water pump
• Apply
shaft to prevent water pump seal damage.
CAUTION
If the right engine cover is installed without greasing the pump shaft, the pump seal could damage.
are two knock pins [A] on the mating surfaces of
• There
the crankcase and right engine cover .
the breather hose [B] into the clamp [C] and position
• Run
it with the right engine cover mounting bolt as shown.
5-8 ENGINE RIGHT SIDE
Right Engine Cover
the release lever [A] is turned to the right [B] lightly,
• When
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].
the new right engine cover gasket in position with a
• Stick
thin layer of grease.
a high temperature grease kick shaft oil seal lips
• Apply
and kick shaft spline.
the right engine cover bolts and kick shaft mount• Torque
ing bolt.
Torque - Right Engine Cover Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
Kick Pedal Bolt: 12 N·m (1.2 kgf·m, 89 in·lb)
the clutch cable and the cooling hoses according to
• Run
the Cable, Wire, and Hose Routing section in the General
•
•
•
•
Information chapter.
Adjust the clutch cable (see this chapter).
Check the clutch release lever angle.
Fill the crankcase with engine oil (see Engine Bottom
End/Transmission chapter).
Fill the engine with coolant (see Cooling System chapter).
CAUTION
Do not remove the clutch release shaft unless it is
absolutely necessary. If removed, you must replace
the oil seal with a new one.
to the cooling system chapter for water pump seal
• Refer
and water pump bearing removal.
ENGINE RIGHT SIDE 5-9
Right Engine Cover
Right Engine Cover Disassembly
the right engine cover (see this chapter).
• Remove
• Pull out the clutch release shaft [A].
CAUTION
Do not remove the clutch release shaft unless it is
absolutely necessary. If removed, you must replace
the oil seal with a new ones.
to the cooling system chapter for water pump seal
• Refer
and water pump bearing removal.
Right Engine Cover Assembly
the oil level gauge, needle bearings and oil seal
• When
were removed, note the following .
○Set the new oil level gauge [A] so that its metal portion [B]
faces outward and press in the gauge until it is bottomed.
○Press the new lower needle bearing [C] until it is bottomed. As for the installation direction, both sides are
available.
○Set the new upper needle bearing [D] with the marked
side facing out and press bearing until it is bottomed.
○Press the new oil seals [E] until they are bottomed and
apply a little high temperature grease [F] on the rips.
to the Cooling System chapter for water pump seal
• Refer
and water pump bearing installation.
5-10 ENGINE RIGHT SIDE
Clutch
Clutch Removal
the right engine cover (see Right Engine Cover
• Remove
Removal).
the clutch pusher [A], shim [B] (as required) and
• Remove
spring plate pusher [C].
the magneto cover.
• Remove
Hold
the
• holder [A].magneto flywheel steady with flywheel & pulley
Special Tool - Flywheel & Pulley Holder: 57001-1605
• Remove:
Clutch Hub Nut [A]
Clutch Spring Bolts [B]
Clutch Spring Holder [C]
Clutch Hub [D]
• Remove:
Friction Plates and Steel Plates
Clutch Wheel
Clutch Housing
Sleeve and Washers
Clutch Installation
molybdenum disulfide grease to the outside of the
• Apply
sleeve and clutch housing bearing hole.
• Install:
Thrust Washers [A]
Sleeve [B]
Clutch Housing [C]
Clutch Wheel [D]
Friction Plates and Steel Plates [E]
Clutch Hub [F]
ENGINE RIGHT SIDE 5-11
Clutch
CAUTION
If dry steel plates and friction plates are installed,
apply transmission oil to the surfaces of each plate
to avoid clutch plate seizure.
○Install the friction plates and steel plates, starting with a
friction plate and alternating them, finishing with a friction
plate.
○Install the hub nut and clutch spring bolts.
Torque - Clutch Hub Bolt: 64 N·m (6.5 kgf·m, 47 ft·lb)
Clutch Spring Bolts: 9.3 N·m (0.95 kgf·m, 82 in·lb)
molybdenum disulfide grease to the clutch spring
• Apply
plate pusher.
• Install:
Clutch Spring Plate Pusher
Shim (as required)
Clutch Pusher
Magneto Cover
Engine Right Side Cover
Friction and Steel Plates Wear, Damage Inspection
inspect the friction and steel plates to see if they
• Visually
show any signs of seizure, or uneven wear.
•
If any plates show signs of damage, replace the friction
plates and steel plates as a set.
Measure the thickness [A] of the friction plates [B] and
steel plates with vernier calipers.
If they have worn past the service limit, replace them with
new ones.
Friction Plate Thickness
3.1 ∼ 3.3 mm
Standard:
Service Limit:
2.9 mm
Steel Plate Thickness
1.47 ∼ 1.73 mm
Standard:
Service Limit:
1.37 mm
Friction and Steel Plate Warp Inspection
each friction plate or steel plate on a surface plate,
• Place
and measure the gap between the surface plate [A] and
each friction plate or steel plate [B] with a thickness gauge
[C] The gap is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it with
a new one.
Friction and Steel Plates Warp
Standard:
Friction Plate
Not more than 0.2 mm
Steel Plate
Not more than 0.15 mm
Service Limit:
Friction Plate
0.3 mm
Steel Plate
0.3 mm
5-12 ENGINE RIGHT SIDE
Clutch
Spring Free Length Measurement
the spring [A] becomes shorter as it weakens,
• Since
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
28.1 mm
Standard:
Service Limit:
26.7 mm
Friction Plate/Clutch Housing Clearance Inspection
the clearance between the tongues [A] on the
• Measure
friction plate and the fingers [B] of the clutch housing.
If this clearance is excessive, the clutch will be noisy.
If the clearance exceeds the service limit, replace the friction plates.
Friction Plate/Clutch Housing Clearance
0.3 ∼ 0.6 mm
Standard:
Service Limit:
0.9 mm
Clutch Hub Spline Inspection
inspect where the teeth on the steel plates wear
• Visually
against the splines [A] of the clutch hub.
If there are notches worn into the splines, replace the
clutch hub. Also, replace the clutch plates if their teeth
are damaged.
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 external shift mechanism.
out the external shift mechanism [A], lifting the engine
• Pull
[B].
the gear set lever spring [C].
• Remove
Remove
the
• [D] [E]. lever set screw [D] and take off the set levers
External Shift Mechanism Installation
the return spring [A] so that the large round edge
• Install
side faces in.
installing the shift shaft, apply high temperature
• Before
grease to the oil seal lips and shift shaft splines.
• Tighten the gear set lever screw.
Torque - Gear Set Lever Screw: 8.8 N·m (0.90 kgf·m, 78
in·lb)
Shift Pedal Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
External Shift Mechanism Inspection
the shift shaft [A] for bending or damage to the
• Check
splines.
•
•
If the shaft is bent, straighten or replace it. If the splines
are damaged, replace the external shift mechanism.
Check the return spring [B] and arm spring [C] for cracks
or distortion.
If the springs are damaged in any way, replace them.
Check the shift mechanism arm [D] for distortion.
If the shift mechanism arm is damaged in any way, replace the shift mechanism.
the gear set levers, and its spring for cracks or
• Check
distortion.
If the lever or spring is damaged in any way, replace them.
5-14 ENGINE RIGHT SIDE
Primary Gear
Primary Gear Removal
the right engine cover (see Right Engine Cover
• Remove
Removal)
the circlip [A], and take off the primary gear [B]
• Remove
and water pump drive gear .
Special Tools - Outside Circlip Pliers: 57001-144
Primary Gear Installation
the water pump drive gear [A] and primary gear [B] on
• Put
the crankshaft [C]. For the both gears, installation either
obverse or reverse side is available.
Primary Gear Removal (KX65A6F ∼)
the right engine cover (see Right Engine Cover
• Remove
Removal).
the magneto cover.
• Remove
Remove
the
• gear [B]. primary gear nut [A], washer, and the primary
○Primary gear nut is left-hand threads.
NOTE
○Use the fly wheel & pulley holder to prevent the crankshaft from the rotating.
Special Tools - Flywheel & Pulley Holder: 57001-1605
Primary Gear Installation (KX65A6F ∼)
the primary gear [A] to the crankshaft then hollow
• Insert
side facing to the outside.
• Install:
Spring Washer [B]
Primary Gear Nut [C]
ENGINE RIGHT SIDE 5-15
Primary Gear
the spring washer [A] with the concave side facing
• Install
to the inward.
• Temporarily tighten the primary gear nut [B].
the primary gear nut
•○Tighten
Primary gear nut is left-hand threads.
Torque - Primary Gear Nut: 49 N·m (5.0 kgf·m, 36 ft·lb)
Special Tools - Flywheel & Pulley Holder: 57001-1605
NOTE
○Use the fly wheel & pulley holder to prevent the crankshaft from the rotating.
• Install:
Right Engine Cover (see Right Engine Cover)
Magneto Cover
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].
Kickshaft Installation
• Torque the ratchet guide bolt and screw.
Torque - Ratchet Guide Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
Ratchet Guide Screw: 5.2 N·m (0.53 kgf·m, 46
in·lb)
Kickstarter Assembly Disassembly/Assembly
kickstarter assembly consists of the following parts.
• The
Check
kickstarter assembly parts for damage. Any
• damagedtheparts
should be replaced with new ones.
A. Idle Gear
B. Circlip
C. Washer
D. Spring
E. Ratchet Gear
F. Kick Gear
G. Kick Shaft
H. Kick Spring
I. Spring Guide
molybdenum disulfide grease to the inside of the
• Apply
kick gear and ratchet gear.
assembling the ratchet gear [A] onto the kick shaft
• When
[B], align the notch [C] on the ratchet gear with the hole
•
[D] on the kick shaft.
Replace the circlips that were removed with new ones.
Special Tool - Outside Circlip Pliers: 57001-144
Idle Gear Removal
• Remove:
Right Engine Cover (see Right Engine Cover Removal)
•
Clutch Housing (see Clutch Removal)
Remove the circlip [A] and pull off the idle gear [B].
Special Tool - Outside Circlip Pliers: 57001-144
Idle Gear Installation
molybdenum disulfide grease to the inside of the
• Apply
idle gear.
• Replace the circlip with a new one.
Special Tool - Outside Circlip Pliers: 57001-144
ENGINE REMOVAL/INSTALLATION 6-1
Engine Removal/Installation
Table of Contents
Exploded View........................................................................................................................
Engine Removal/Installation ...................................................................................................
Engine Removal................................................................................................................
Engine Installation.............................................................................................................
6-2
6-3
6-3
6-4
6
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.
ENGINE REMOVAL/INSTALLATION 6-3
Engine Removal/Installation
Engine Removal
the engine oil (see Engine Bottom End/Transmis• Drain
sion chapter).
the coolant (see Cooling System chapter).
• Drain
Remove:
• Radiator Shrouds
•
Side Covers
Seat
Fuel Tank
Water Hoses
Radiators
Expansion Chamber
Spark Plug
Carburetor (with Cables and Hoses)
Clutch Cable Lower End
Drive Chain
Engine Sprocket
Shift Pedal
Brake Pedal
Disconnect the magneto output lead, and free the leads
from the clamp.
a jack [A] under the frame to lift the motorcycle off
• Place
the ground, and put blocks under the front and rear tires
to steady the motorcycle.
WARNING
The swingarm pivot shaft also serves as the engine mounting bolt. Take precautions to insure the
frame is well supported, and that the motorcycle
will not fall over when the pivot shaft is removed.
Special Tool - Jack: 57001-1238
the engine mounting bolts [B].
• Remove
Pull
out
the
swing arm pivot shaft [C].
• Lift the engine
out to the right.
•
6-4 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Installation
the engine on the frame.
• Install
tightening the engine mounting nuts, measure the
• Before
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 specified value, adjust them
by inserting the shim (Part No. 92180-1354) and tighten
the following nuts.
Torque - Engine Mounting Nuts:
25 N·m (2.5 kgf·m, 18 ft·lb)
29 N·m (3.0 kgf·m, 21 ft·lb): KX65-A3 ∼
Swing Arm Pivot Shaft Nut: 69 N·m (7.0 kgf·m, 51
ft·lb)
Shift Pedal Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
route the leads, cables and hoses, refer to the General
• To
Information chapter.
install parts removed, refer to the appropriate chapters.
• To
Fill
the cooling system with coolant (see Cooling System
• chapter).
the engine with engine oil (see Engine Bottom
• Fill
End/Transmission chapter).
• Adjust:
Throttle Cable
Clutch Cable
Drive Chain
Rear Brake
ENGINE BOTTOM END/TRANSMISSION 7-1
Engine Bottom End/Transmission
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Transmission Oil .....................................................................................................................
Oil Level Inspection...........................................................................................................
Oil Change ........................................................................................................................
Crankcase ..............................................................................................................................
Crankcase Splitting ...........................................................................................................
Crankcase Disassembly ...................................................................................................
Crankcase Assembly ........................................................................................................
Crankshaft, Connecting Rod ..................................................................................................
Crankshaft Removal .........................................................................................................
Crankshaft Installation ......................................................................................................
Crankshaft Disassembly ...................................................................................................
Crankshaft Assembly ........................................................................................................
Connecting Rod Big End Radial Clearance Inspection.....................................................
Connecting Rod Big End Seizure Inspection ....................................................................
Connecting Rod Big End Side Clearance Inspection........................................................
Crankshaft Runout Inspection...........................................................................................
Crankshaft Alignment Inspection ......................................................................................
Transmission ..........................................................................................................................
Shaft Removal ..................................................................................................................
Shaft Installation ...............................................................................................................
Shaft Disassembly ............................................................................................................
Shaft Assembly .................................................................................................................
Shift Drum and Fork Installation........................................................................................
Shift Fork Bending Inspection ...........................................................................................
Shift Fork/Gear Groove Wear Inspection..........................................................................
Shift Fork Guide Pin/Shift Drum Groove Wear Inspection ................................................
Gear Damage Inspection ..................................................................................................
Gear Dog/Gear Dog Hole Damage Inspection .................................................................
Ball Bearing Wear Inspection............................................................................................
7-2
7-4
7-5
7-5
7-5
7-7
7-7
7-8
7-8
7-10
7-10
7-10
7-10
7-10
7-11
7-11
7-11
7-11
7-12
7-13
7-13
7-13
7-13
7-13
7-14
7-15
7-15
7-15
7-16
7-16
7-16
7
7-2 ENGINE BOTTOM END/TRANSMISSION
Exploded View
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-A1 ∼ A5
16. KX65-A1 ∼ A6
T1: 20 N·m (2.0 kgf·m, 15 ft·lb)
T2: 29 N·m (3.0 kgf·m, 21 ft·lb)
T3: 8.8 N·m (0.90 kgf·m, 78 in·lb)
T4: 8.8 N·m (0.90 kgf·m, 78 in·lb)
T5: 24 N·m (2.4 kgf·m, 17 ft·lb)
T6: 8.8 N·m (0.90 kgf·m, 78 in·lb)
T7: 5.2 N·m (0.53 kgf·m, 46 in·lb)
EO: Apply engine oil to the transmission gears and shift forks, etc.
G: Apply high temperature grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket to the left and right case mating surface.
M: Apply molybdenum disulfide grease.
O: Apply 2-stroke engine oil.
R: Replacement parts
7-4 ENGINE BOTTOM END/TRANSMISSION
Specifications
Item
Transmission Oil:
Engine Oil:
Grade
Viscosity
Capacity
Crankshaft, Connecting Rod
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Radial Clearance
Connecting Rod Big End Side Clearance
Crankshaft Runout
Transmission
Shift Fork Ear Thickness
Gear Shift Fork Groove Width
Shift Fork Guide Pin Diameter
Shift Drum Groove Width
Standard
Service Limit
API SE, SF or SG
API SH, SJ or SL with JASO MA
SAE10W-40
0.5 L
– – –
Not more than 0.05 mm/100 mm
Not more than 0.05 mm/100 mm
0.025 ∼ 0.037 mm
0.35 ∼ 0.45 mm
Not more than 0.03 mm
0.2 mm/100 mm
0.2 mm/100 mm
0.09 mm
0.65 mm
0.05 mm
3.90
4.05
5.90
6.05
∼
∼
∼
∼
4.00
4.15
6.00
6.20
mm
mm
mm
mm
Special Tools - Bearing Puller Adapter: 57001-136
Outside Circlip Pliers: 57001-144
Bearing Puller: 57001-158
Bearing Driver Set: 57001-1129
Crankcase Splitting Tool Assembly: 57001-1362
Crankshaft Jig: 57001-1439
Sealant - Kawasaki Bond (Liquid Gasket-Silver): 92104-002
– – –
– – –
3.80
4.25
5.80
6.25
mm
mm
mm
mm
ENGINE BOTTOM END/TRANSMISSION 7-5
Transmission Oil
In order for the transmission and clutch to function properly, always maintain the transmission oil at the proper level
and change the oil periodically.
WARNING
Motorcycle operation with insufficient, deteriorated, or contaminated transmission oil will
accelerated wear and may result in transmission
seizure, and injury.
Oil Level Inspection
the motorcycle so that it is perpendicular to the
• Situate
ground.
the motorcycle has just been used, wait several minutes
• Ifuntil
the oil settles.
Check
the oil level comes up between the upper level
• [A] andthat
lower level [B] through the oil level gauge [C] on
the right engine cover .
If the oil level is too high, remove the excess oil through
the oil filler opening using a syringe or some other suitable
device.
If the oil level is too low, add the correct amount of oil.
Use the same type and make of oil that is already in the
engine.
NOTE
○If the engine oil type and make are unknown, use any
brand of the specified oil to top up the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
Oil Change
up the engine thoroughly so that the oil will pick up
• Warm
any sediment and drain easily. Then stop the engine.
an oil pan beneath the engine.
• Place
Remove
the engine oil drain plug [A] on the bottom of the
• engine, and
let the oil drain completely.
NOTE
○Hold the motorcycle upright so that the oil may drain
completely.
7-6 ENGINE BOTTOM END/TRANSMISSION
Transmission Oil
the gasket at the engine oil drain plug for damage.
• Check
Replace the gasket with a new one if it is damaged.
the oil has completely drained out, install the engine
• After
oil drain plug with the gasket, and tighten it.
Torque - Engine Oil Drain Plug: 20 N·m (2.0 kgf·m, 15 ft·lb)
the engine with a good quality engine oil specified be• Fill
low.
• Check the oil level.
Recommended Engine Oil
Grade:
API SE, SF or SG
API SH, SJ or SL with JASO MA
Viscosity:
SAE 10W-40
Engine Oil Capacity
0.5 L
Capacity:
Although 10W-40 engine oil is the recommended oil for
most conditions, the oil viscosity may need to be changed
to accommodate atmospheric conditions in your riding area.
ENGINE BOTTOM END/TRANSMISSION 7-7
Crankcase
Crankcase Splitting
the engine (see the Engine Removal/Installation
• Remove
chapter).
the engine on a clean surface while parts are being
• Set
removed.
• Remove:
Magneto Cover
Output Shaft Sleeve [A] and O-ring [B]
Cylinder Head (see Engine Top End Chapter)
Cylinder (see Engine Top End Chapter)
Piston (see Engine Top End Chapter)
Right Engine Cover (see Engine Right Side Chapter)
Clutch (see Engine Right Side Chapter)
Primary Gear (see Engine Right Side Chapter)
Kickstarter Assembly (see Engine Right Side Chapter)
Kickstarter Idle Gear (see Engine Right Side Chapter)
Gear Set and Neutral Set Levers [A]
Magneto Flywheel and Stator (see Electrical System
Chapter)
• Remove the crankcase bolts [A].
the crankcase splitting tool [A] and adapter [B] into
• Install
the left side of the crankcase. Be certain to screw the tool
in all the way.
Special Tools - Crankcase Splitting Tool Assembly: 57001
-1362
Bearing Puller Adapter: 57001-136
the bolt on the crankcase splitting tool to split the
• Tighten
crankcase halves.
the crankcase is split, remove the crankcase split• Once
ting tool, and lift off the left crankcase half.
7-8 ENGINE BOTTOM END/TRANSMISSION
Crankcase
out the shift rods [A].
• Pull
Disengage
• grooves. the shift fork guide pins from the shift drum
off the shift drum [B]
• Take
Remove
shift forks [C] from the transmission gears.
• Take out the
the
shaft [D] and output shaft [E] together
• with their geardrive
meshed.
Remove
the
crankshaft
from the right crankcase half us• ing a press.
Crankcase Disassembly
CAUTION
Do not remove the bearings and the oil seals unless
it is necessary.
Removal may damage them.
Crankcase Assembly
fitting the left case on the right case, note the fol• Before
lowing:
○Chip off the old gasket from the mating surfaces of the
crankcase halves, and clean off the crankcase with a high
flash-point solvent. After cleaning, apply transmission oil
to the transmission gears, shift drum, shift forks and so
on.
○Be sure to replace any oil seal removed with a new one.
Press in the new oil seal using a press and suitable tools
so that the seal surface is flush with the surface of the
crankcase.
○As for the crankshaft oil seal [A], on the right crankcase
half [B] press in the seal until it is bottomed.
○Apply high temperature grease to the oil seal lips.
○Press in the ball bearings using the bearing driver set until
the bearing is bottomed.
Special Tool - Bearing Driver Set: 57001-1129
○Tighten the drive shaft bearing retaining screws securely.
Torque - Bearing Retaining Screws: 8.8 N·m (0.90 kgf·m, 78
in·lb)
○If the crankshaft bearings stay on the crankshaft when
splitting the crankcase, remove the bearings from the
crankshaft and reinstall them in the crankcase, and then
assemble the crankcase (see Crankshaft Removal and
Installation).
ENGINE BOTTOM END/TRANSMISSION 7-9
Crankcase
the crankshaft [A] to BDC [B], and install the crank• Turn
shaft jig [C] between the flywheels opposite the connecting rod big end to protect flywheel alignment as shown.
Install the suitable shaft [D] to the rear end of the crankshaft jig.
○If the crankshaft has been removed from the crankcase,
install the jig between the crankshaft flywheels before
pressing the crankshaft into the right crankcase half.
Special Tool - Crankshaft Jig: 57001-1439
the transmission shaft as a set (see this chapter).
• Install
Install
the shift fork, shift drum and shift rod.
•
to see that the crankcase knock pins are in place
• Check
on the right crankcase half. If any of them has been removed, replace it with a new one.
liquid gasket to the mating surface [A] of the left
• Apply
crankcase half.
Sealant - Kawasaki Bond (Liquid Gasket - Silver): 92104
-002
a suitable tool on the left crankcase to press [A]
• Using
around the hole for the crankshaft, fit the crankcase
halves together with a press on the tool.
NOTE
○Constantly check the alignment of the two crankcase
halves, and the position of the transmission shafts, and
shift drum. The front and rear of the crankcase must be
pushed together evenly.
the crankshaft jig from the flywheels.
• Remove
Tighten
the
crankcase bolts starting with the ones around
• the crankshaft,
and then the farther ones.
Torque - Crankcase Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
to see that the crankshaft, drive shaft, and output
• Check
shaft all turn freely (in the neutral position).
If the crankshaft will not turn, probably the crankshaft is
not centered; tap the appropriate end of the crankshaft
with a mallet to reposition it.
Spinning the output shaft, shift the transmission through
all the gears to make certain there is no binding and that
all the gears shift properly.
Install the parts removed in the reverse order of removal,
and refer to the appropriate chapters.
○Replace the O-ring on the output shaft with a new one.
•
•
7-10 ENGINE BOTTOM END/TRANSMISSION
Crankshaft, Connecting Rod
Crankshaft Removal
the crankcase (see Crankcase Splitting).
• Split
the transmission shafts (see Transmission Shaft
• Remove
Removal).
a press, remove the crankshaft from the right
• Using
crankcase.
○If the bearings stay on the crankshaft when splitting the
crankcase or removing the crankshaft from the right
crankcase, remove the bearings from the crankshaft with
a bearing puller [A] and adapter [B].
Special Tools - Bearing Puller: 57001-158
Bearing Puller Adapter: 57001-136
Crankshaft Installation
installing the crankshaft bearings [B], apply high
• When
temperature grease to the outer sides of the bearings,
and then press them into the crankcase using the bearing
driver [A] until the bearing bottoms against the step.
○Position the crankcase half so that the main bearing housing is seated on a suitable press fixture.
○Install the crankshaft bearing so that the sealed side in (to
the oil seal [C] side).
Special Tool - Bearing Driver Set: 57001-1129
the crankshaft jig [A] between the crankshaft fly• Insert
wheels opposite the connecting rod big end to protect
flywheel alignment as shown, and using a suitable tool
[B] on the left crankcase to press around the hole for the
crankshaft.
○When pressing, position the jig in the crankcase opening
so the jig does not hit the crankcase.
Special Tool - Crankshaft Jig: 57001-1439
• Apply 2-stroke oil to the connecting rod big end bearing.
Crankshaft Disassembly
Since assembly of the crankshaft demands exacting tolerances, the disassembly and reassembly of the crankshaft
can only be done by a shop having the necessary tools and
equipment.
If it should be necessary to disassemble the crankshaft,
use a press to remove the crankpin.
•
Crankshaft Assembly
Since the assembly of the crankshaft demands exacting
tolerances, the disassembly and reassembly of the crankshaft can only be done by a shop having the necessary tools
and equipment.
Reassemble the crankshaft according to the standard tolerances in Specifications.
○Connecting rod bend, twist
○Connecting rod big end radial clearance.
○Cold-fitting tolerance between crankpin and flywheels.
○Side clearance between the connecting rod big end and
one of flywheels.
○Crankshaft runout.
•
ENGINE BOTTOM END/TRANSMISSION 7-11
Crankshaft, Connecting Rod
Connecting Rod Big End Radial Clearance Inspection
the crankshaft in a flywheel alignment jig or on V
• Set
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 difference between the two
gauge readings is the radial clearance.
If the radial clearance exceeds the service limit, the crankshaft should be either replaced or disassembled and the
crankpin, needle bearing, and connecting rod big end examined for wear.
Connecting Rod Big End Radial Clearance
0.025 ∼ 0.037 mm
Standard:
Service Limit: 0.09 mm
Connecting Rod Big End Seizure Inspection
In case of serious seizure with damaged flywheels, the
crankshaft must be replaced.
In case of less serious damage, disassemble the crankshaft and replace the crankpin, needle bearing, side
washers, and connecting rod.
Connecting Rod Big End Side Clearance Inspection
the side clearance [A] of the connecting rod with
• Measure
a thickness gauge.
If the clearance exceeds the service limit, replace the
crankshaft.
Connecting Rod Big End Side Clearance
Standard:
0.35 ∼ 0.45 mm
Service Limit:
0.65 mm
Crankshaft Runout Inspection
the crankshaft in a flywheel alignment jig or on V
• Set
blocks, and place a dial gauge against the points indi-
•
cated.
Turn the crankshaft slowly. The maximum difference in
gauge readings is the crankshaft runout.
If the runout at either point exceeds the service limit, align
the flywheels so that the runout falls within the service
limit.
Crankshaft Runout
Standard:
Not more than 0.03 mm
Service Limit:
0.05 mm
[A]:
7.5 mm
7-12 ENGINE BOTTOM END/TRANSMISSION
Crankshaft, Connecting Rod
Crankshaft Alignment Inspection
the case of horizontal misalignment, which is the most
• Incommon,
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, repeating the
process until the runout falls within the service limit.
○Vertical misalignment is corrected either by driving a
wedge in between the flywheels or by squeezing the
flywheel rims in a vise, depending on the nature of the
misalignment. In cases of both horizontal and vertical
misalignment, correct the horizontal misalignment first.
•
CAUTION
Don’t hammer the flywheel at point "A".
If flywheel misalignment cannot be corrected by the above
method, replace the crankpin or the crankshaft itself.
ENGINE BOTTOM END/TRANSMISSION 7-13
Transmission
Shaft Removal
the crankcase (see Crankcase Splitting).
• Split
off the shift rods [A], and disengage the shift fork
• Pull
guide pins from the shift drum grooves.
the shift drum [B]
• Remove
Remove
the
forks [C] from the transmission gears.
• Take out the shift
drive shaft [D] and output shaft [E] together,
• with their gears
meshed.
Shaft Installation
the drive shaft [A] and output shaft [B] together, with
• Hold
their gears meshed, and fit them into the right crankcase
•
half.
To install the shift forks and shift drum, see the Shift Drum
and Fork Installation.
Shaft Disassembly
the transmission shafts (see Shaft Removal).
• Remove
circlip pliers to remove the circlips, disassemble the
• Using
transmission shaft.
Special Tool - Outside Circlip Pliers: 57001-144
Shaft Assembly
transmission oil liberally to the transmission shaft,
• Apply
gears and bearings.
any circlips that were removed with new ones.
•○Replace
Always install circlips [A] so that the opening [B] is aligned
with a spline groove [C].
Special Tool - Outside Circlip Pliers: 57001-144
drive shaft gears can be identified by size; the small• The
est diameter gear is 1st gear, and the largest is 6th. Be
sure that all parts are put back in the correct sequence,
and facing the proper direction, and that all circlips and
the washers are properly in place.
[A] 1st Gear (13T; part of drive shaft)
[B] 6th Gear (24T; plain side faces right)
[C] 3rd/4th Gear (18T/21T; larger gear faces left)
[D] 5th Gear (23T; plain side faces left)
[E] 2nd Gear (16T; either side may face in)
[F] Circlip (1.2 × 15 × 19)
7-14 ENGINE BOTTOM END/TRANSMISSION
Transmission
output shaft gears can be identified by size; the
• 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 right)
[B] 5th Gear (28T; fork groove goes to the right side of
the gear teeth)
[C] 4th gear (30T; dog recesses face left)
[D] 3rd gear (31T; dog recesses face right)
[E] 6th gear (26T; fork groove goes to the left side of the
gear teeth)
[F] 1st gear (37T; plain side faces right)
[G] Circlip (1.2 × 18)
[H] Circlip (1.2 × 18 ×23.5)
that each gear spins or slides freely on the trans• Check
mission shaft without binding after assembly.
Shift Drum and Fork Installation
a little transmission oil to the shift fork ears, and fit
• Apply
the shift forks into the gear grooves.
Shift Fork Identification
Drive shaft 3rd gear and 4th
gear shift fork [A]
ears are shorter than those of
the other two shift forks
Output shaft 5th and 6th gear ears are longer than the drive
shaft 3rd/4rd gear shift fork
shift forks [B]
ENGINE BOTTOM END/TRANSMISSION 7-15
Transmission
the shift drum.
• Install
Fit
the
shift fork guide pins into the corresponding shift
• drum grooves.
a little transmission oil to the shift rods, and slide
• Apply
them into the shift forks.
the shift drum with the suitable tool and tighten
• Holding
the shift drum operating plate bolt.
○Apply a non-permanent locking agent to the shift drum
operating plate bolt.
Torque - Shift Drum Operating Plate Bolt: 24 N·m (2.4
kgf·m, 17 ft·lb)
Shift Fork Bending Inspection
inspect the shift forks, and replace any fork that is
• Visually
bent. A bent fork could cause difficulty in shifting, or allow
the transmission to jump out of gear when under power.
[A] 90°
Shift Fork/Gear Groove Wear Inspection
the thickness of the shift fork ears [A], and mea• Measure
sure the width [B] of the shift fork grooves in the transmission gears.
If the thickness of a shift fork ear is less than the service
limit, the shift fork must be replaced.
Shift Fork Ear Thickness
3.90 ∼ 4.00 mm
Standard:
Service Limit:
3.80 mm
If a gear shift fork groove is worn over the service limit,
the gear must be replaced.
Shift Fork Groove Width
4.05 ∼ 4.15 mm
Standard:
Service Limit:
4.25 mm
Shift Fork Guide Pin/Shift Drum Groove Wear
Inspection
the diameter [A] of each shift fork guide pin, and
• Measure
measure the width [B] of each shift drum groove.
If the guide pin on any shift fork is less than the service
limit, the fork must be replaced.
Shift Fork Guide Pin Diameter
5.90 ∼ 6.00 mm
Standard:
Service Limit:
5.80 mm
If any shift drum groove is worn over the service limit, the
drum must be replaced.
Shift Drum Groove Width
6.05 ∼ 6.20 mm
Standard:
Service Limit: 6.25 mm
7-16 ENGINE BOTTOM END/TRANSMISSION
Transmission
Gear Damage Inspection
inspect the gear teeth on the transmission gears.
• Visually
Repair lightly damaged gear teeth with an oilstone. The
gear must be replaced if the teeth are badly damaged.
When gear is repaired or replaced, the driving gear should
also be inspected and repaired or replaced if necessary.
Gear Dog/Gear Dog Hole Damage Inspection
inspect the gear dogs [A] and gear dog holes [B].
• Visually
Replace any damaged gears or gears with excessively
worn dogs or dog holes.
Ball Bearing Wear Inspection
the ball bearing on the crankcase.
• Check
Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel rather than measurement. Clean each bearing in a high flash-point solvent, dry it (do not spin the bearing while it is dry), and oil
it with transmission oil.
○Spin the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any
rough spots, replace it.
WHEELS/TIRES 8-1
Wheels/Tires
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Wheels (Rims) ........................................................................................................................
Front Wheel Removal .......................................................................................................
Front Wheel Installation ....................................................................................................
Rear Wheel Removal........................................................................................................
Rear Wheel Installation.....................................................................................................
Wheels Inspection.............................................................................................................
Spoke Inspection ..............................................................................................................
Rim Inspection ..................................................................................................................
Axle Inspection..................................................................................................................
Tires........................................................................................................................................
Air Pressure Inspection/Adjustment..................................................................................
Tires Inspection.................................................................................................................
Tire Removal.....................................................................................................................
Tire Installation..................................................................................................................
Hub Bearings..........................................................................................................................
Hub Bearing Removal.......................................................................................................
Hub Bearing Installation....................................................................................................
Bearing Inspection ............................................................................................................
8-2
8-3
8-4
8-4
8-4
8-5
8-6
8-7
8-7
8-8
8-8
8-9
8-9
8-9
8-10
8-11
8-12
8-12
8-12
8-13
8
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.
WHEELS/TIRES 8-3
Specifications
Item
Wheels (Rims):
Rim Size:
Front
Rear
Rim Runout:
Axial
Radial
Axle Runout/100 mm
Tires Air Pressure
Front and Rear
Tires
Standard Tire:
Front:
Size
Make
Type
Rear:
Size
Make
Type
Standard
Service Limit
14 × 1.40
12 × 1.60
1.0 mm or less
1.0 mm or less
0.1 mm
2 mm
2 mm
0.2 mm
98 kPa (1.0 kgf/cm², 14 psi)
– – –
60/100-14 30M
DUNLOP
D755F, Tube (KX65-A1 ∼ A6)
D756F, Tube
– – –
80/100-12 41M
DUNLOP
D755, Tube (KX65-A1 ∼ A6)
D756, Tube
– – –
Special Tools - Inside Circlip Pliers: 57001-143
Rim Protector: 57001-1063
Bead Breaker Assembly: 57001-1072
Bearing Driver Set: 57001-1129
Jack: 57001-1238
8-4 WHEELS/TIRES
Wheels (Rims)
Front Wheel Removal
the jack [A] under the frame, and stabilize the mo• Using
torcycle.
Special Tool - Jack: 57001-1238
a stand under the engine to raise the front wheel
• Place
the ground.
the cotter pin [A]
• Remove
Unscrew
the axle nut [B].
•
the axle [A], and pull out the wheel. Take off the
• Remove
collar [B] and cap [C] from each side of the front hub.
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so the disc does not
touch the ground.
a wood wedge between the disc brake pads. This
• Insert
prevents them from being moved out of their proper position, should the brake lever be squeezed accidentally.
Front Wheel Installation
grease [A] to the seals.
• Apply
the projection on the cap to the groove on the collar.
• Fit
Install
caps [B] collars [C] on the left and right side of
• the hub.theThe
collars and caps are the same.
Insert
the
axle
from left side.
• Tighten the front[D]axle
nut [E].
•
Torque - Front Axle Nut: 79 N·m (8.0 kgf·m, 58 ft·lb)
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 the cotter pin [A] over the nut [B].
the jack.
• Remove
Check
the
• brake drag.front brake for good braking power and no
WARNING
Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.
Rear Wheel Removal
the jack under the frame so that the rear wheel is
• Using
raised off the ground.
Special Tool - Jack: 57001-1238
the clip [A] from the master link using pliers, and
• Remove
free the drive chain [B] from the rear sprocket.
8-6 WHEELS/TIRES
Wheels (Rims)
the cotter pin [A].
• Remove
Remove
the axle nut [B].
• Pull out the
[C].
• Move the rearaxlewheel
with the rear caliper installed.
• Take off the collar andback
cap
from the each side of the rear
• hub.
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so the disc does not
touch the ground.
a wood wedge between the brake pads. This pre• Insert
vents them from being moved out of their proper position,
should the brake pedal be squeezed accidentally.
Rear Wheel Installation
the brake holder stop [A] against the stop projection
• Fit
[B] on the swingarm.
grease [A] to the seals.
• Apply
Fit
the
projection on the cap to the groove on the collar.
• Install the
caps [B] and collars [C] on the left (longer collar)
• and right (shorter
collar) side of the hub.
the drive chain. Install the clip [A] so that the closed
• Install
end of the "U" [B] points in the direction of chain rotation
[C].
the drive chain slack (see Final Drive chapter).
• Check
• Insert the axle from left side and tighten the rear axle nut.
Torque - Rear Axle Nut: 79 N·m (8.0 kgf·m, 58 ft·lb)
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 the cotter pin [A] over the nut [B].
the rear brake for good braking power and no
• Check
brake drag.
WARNING
Do not attempt to drive the motorcycle until a full
brake pedal is obtained by pumping the brake pedal
until the pads are against the disc. The brake will
not function on the first application of the pedal if
this is not done.
Wheels Inspection
the jack under the frame so that the front/rear wheel
• Place
is raised off the ground.
Special Tool - Jack: 57001-1238
the wheel lightly, and check for roughness or binding.
• Spin
If roughness or binding is found, replace the hub bearings.
inspect the front and rear axles for damage.
• Visually
If axle is damaged or bent, replace it.
Spoke Inspection
that all the spokes are tightened evenly.
• Check
If spoke tightness is uneven or loose, tighten the spoke
nipples evenly.
Torque - Spoke Nipples: 1.5 N·m (0.15 kgf·m, 13 in·lb)
• Check the rim runout.
WARNING
If any spoke breaks, it should be replaced immediately. A missing spoke places an additional load on
the other spokes, which will eventually cause other
spokes to break.
8-8 WHEELS/TIRES
Wheels (Rims)
Rim Inspection
the wheel, and support it with the tire by the axle.
• Remove
the rim runout, axial [A] and radial [B], with a dial
• Measure
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 (runout). A certain amount of rim warp can be corrected by recentering the rim. Loosen some spokes and
tighten parts of the rim. If the rim is badly bent, however,
it must be replaced.
Rim Runout (with tire installed)
Standard:
Axial
TIR 0.8 mm or less
Radial
TIR 1.0 mm or less
Service Limit:
Axial
TIR 2.0 mm
Radial
TIR 2.0 mm
Axle Inspection
inspect the front and rear axle for damages.
• Visually
If the axle is damaged or bent, replace it.
the axle in V blocks that are 100 mm [A] apart, and
• Place
set a dial gauge on the axle at a point halfway between
the blocks. Turn the axle to measure the runout. The
difference between the highest and lowest dial readings
is the amount of runout.
If runout exceeds the service limit, replace the axle.
Axle Runout/100 mm
Under 0.1 mm
Standard:
Service Limit:
0.2 mm
WHEELS/TIRES 8-9
Tires
Air Pressure Inspection/Adjustment
tire air pressure gauge [A], measure the tire pres• Using
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 recommended pressure.
Track Condition
Tire Pressure
When the track is wet, muddy, sandy
or slippery, reduce the tire pressure to
increase the tire tread surface on the
ground.
80 kPa
(0.8 kgf/cm², 11 psi)
↑
When the track is pebbly or hard,
increase the tire pressure to prevent
damage or punctures, through the
tires will skid more easily.
↓
98 kPa
(1.0 kgf/cm², 14 psi)
Tires Inspection
As the tire tread wears down, the tire becomes more susceptible the puncture and failure.
Remove any imbedded stones or other foreign particles
from the tread.
Visually inspect the tire for cracks and cuts, replacing the
tire in case of bad damage. Swelling or high spots indicate internal damage, requiring tire replacement.
•
•
WARNING
To ensure safe handling and stability, use only the
recommended standard tires for replacement, inflated to the standard pressure.
NOTE
○Check and balance the wheel when a tire is replaced
with a new one.
Standard Tire
Front:
Size:
60/100-14 30M
Make:
DUNLOP
Type:
D755F, Tube (KX65-A1 ∼ A6)
D756F, Tube
Rear:
Size:
80/100-12 41M
Make:
DUNLOP
Type:
D755, Tube (KX65-A1 ∼ A6)
D756, Tube
8-10 WHEELS/TIRES
Tires
Tire Removal
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so the disc does not
touch the ground.
the wheel from the motorcycle (see Wheels Re• Remove
moval).
maintain wheel balance, mark [A] the valve stem posi• To
tion on the tire with chalk so that the tire can be reinstalled
in the same position.
Take out the valve core [B] to let out the air.
Remove the valve stem nut [C].
○When handling the rim, be careful not to damage the rim
flanges.
Remove the bead protector nut.
Lubricate the tire beads and rim flanges on both sides with
a soap and water solution or rubber lubricant. This helps
the tire beads slip off the rim flanges.
•
•
•
•
CAUTION
Never lubricate with mineral oil (engine oil) or gasoline because they will cause deterioration of the tire.
the beads away from both sides of the rim with the
• Break
bead breaker [A].
Special Tool - Bead Breaker Assembly: 57001-1072
on the side of the tire opposite valve stem, pry the
• Step
tire off the rim with the tire iron [A] of the bead breaker
protecting the rim with rim protectors [B].
Special Tools - Rim Protector: 57001-1063
Tire Iron Protection of the Bead Breaker Assembly: 57001-1072
CAUTION
Take care not to insert the tire irons so deeply that
the tube gets damaged.
the tube when one side of the tire is pried off.
• Remove
Pry
the
tire
off the rim.
•
WHEELS/TIRES 8-11
Tires
Tire Installation
the rim and tire, and replace them if necessary.
• Inspect
the tube.
• Install
Apply
a
solution, or rubber lubricant to the
• rim flangesoapandandtirewater
beads.
the tire on the rim so that the valve [A] is at the tire
• Position
balance mark [B] (the chalk mark made during removal,
•
•
or the yellow paint mark on a new tire. see Tire Removal).
Insert the valve stem into the rim, and screw the nut on
loosely.
Fit the rim protectors and use tire irons to install the tire
bead.
NOTE
○To prevent rim damage, be sure to place the rim protectors at any place the tire irons are applied.
one side of the tire back onto the rim. Fit the bead
• Pry
protector into the tire.
the other side of the tire onto the rim, starting at the
• Pry
side opposite the valve.
○Take care not to insert the tire irons so deeply that the
•
•
•
•
tube is damaged.
Install the other side of the tire bead onto the rim in the
same manner.
Check that the tube is not pinched between the tire and
rim.
Tighten the bead protector nut and valve stem nut, and
put on the valve cap.
Check and adjust the air pressure after installing.
8-12 WHEELS/TIRES
Hub Bearings
Hub Bearing Removal
• Remove the wheel (see Wheel Removal).
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
the oil seals and circlip.
• Remove
Remove
the hub bearing by tapping evenly around the
• bearing inner
race as shown.
[A] Bar
[B] Distance Collar
[C] Hub Bearing
Hub Bearing Installation
installing the wheel bearings, blow any dirt or for• Before
eign particles out of the hub with compressed air to pre-
•
vent contamination of the bearings.
Install the bearings [A] by using the bearing driver set [B]
which does not contact the bearing inner race.
Special Tool - Bearing Driver Set: 57001-1129
○Install
NOTE
the bearings so that the marked side, or the
sealed side faces out.
○Press in the bearings as follows.
○When the bearings are installed in the front hub [A], press
in the right side bearing [B] until it is bottomed against the
step [C] of the hub. And press in the left side bearing [D]
until it is bottomed against the collar [E].
○When the bearings are installed in the rear hub [A], press
in the left side bearing [B] until it is bottomed against the
step [C] of the hub. And press in the right side bearing [D]
until it is bottomed against the collar [E].
WHEELS/TIRES 8-13
Hub Bearings
the circlip and oil seals with new ones.
• Replace
Press
in
the
oil seals [A] so that the seal surface is flush
• [B] with the end
of the hole.
Apply
high
temperature
grease to the oil seal lips.
•
Special Tool - Bearing Driver set: 57001-1129 [C]
Inside Circlip Pliers: 57001-143
Bearing Inspection
NOTE
○It is not necessary to remove any bearings for inspection. If any bearings are removed, they will need to be
replaced with new ones.
[A] it by hand to check its condition.
• Spin
If it is noisy, does not spin smoothly, or has any rough
•
spots, it must be replaced.
Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
FINAL DRIVE 9-1
Final Drive
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Drive Chain.............................................................................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Slack Adjustment ..........................................................................................
Wheel Alignment Inspection .............................................................................................
Wheel Alignment Adjustment............................................................................................
Drive Chain Wear Inspection ............................................................................................
Drive Chain Lubrication.....................................................................................................
Drive Chain Removal ........................................................................................................
Drive Chain Installation .....................................................................................................
Sprockets................................................................................................................................
Engine Sprocket Removal ................................................................................................
Engine Sprocket Installation ............................................................................................
Rear Sprocket Removal....................................................................................................
Rear Sprocket Installation.................................................................................................
Sprocket Wear Inspection.................................................................................................
Rear Sprocket Warp Inspection ........................................................................................
9-2
9-3
9-4
9-4
9-4
9-5
9-5
9-5
9-6
9-6
9-7
9-8
9-8
9-8
9-8
9-8
9-8
9-9
9
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 grease.
L: Apply a non-parmanent locking agent.
O: Apply oil.
R: Replacement Parts
FINAL DRIVE 9-3
Specifications
Item
Drive Chain
Chain Slack
Chain 20-link Length
Standard Chain:
Make
Type
Length
Sprocket
Engine Sprocket Diameter
Rear Sprocket Warp
Standard
44 ∼ 54 mm
45 ∼ 55 mm (KX65-A3 ∼)
254.0 ∼ 254.6 mm
DAIDO
DID 420MBK1
108 Links
110 Links (KX65-A3 ∼)
44.70 ∼ 44.90 mm/13T
Under 0.4 mm
Special Tools - Outside Circlip Pliers: 57001-144
Jack: 57001-1238
Service Limit
– – –
– – –
259 mm
–
–
–
–
–
–
–
–
–
–
–
–
44.0 mm
0.5 mm
9-4 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection
the motorcycle on its stand.
• Support
the wheel alignment (see Wheel Alignment Inspec• Check
tion), and adjust it if necessary (see Wheel Alignment Adjustment).
NOTE
○Clean the drive chain if it is dirty, and lubricate it if it
appears dry.
the rear wheel to find the position where the chain
• Rotate
is tightest.
the space (chain slack) [A] between the chain
• Measure
and the swingarm at the rear of the chain slipper with the
rear wheel raised off the ground.
If the drive chain slack exceeds the standard, adjust it.
Chain Slack
Standard:
KX65-A1 ∼
A2
44 ∼ 54 mm
KX65-A3 ∼
45 ∼ 55 mm
Drive Chain Slack Adjustment
the left and right chain adjuster locknuts [A].
• Loosen
Remove
the cotter pin [B] and loosen the axle nut [C].
• If the chain
is too tight, back out the left and right chain
adjusting bolts [D] evenly, and push the wheel forward
until the chain is too loose.
If the chain is too loose, turn both chain adjusting bolts
evenly until the drive chain has the correct amount of
slack. To keep the chain and wheel properly aligned, the
rear end of the left chain adjuster should align with the
same swingarm mark [E] as the rear end [F] of the right
chain adjuster.
the wheel alignment.
• Check
both chain adjuster locknuts securely.
• Tighten
Tighten
the axle nut.
•
Torque - Rear Axle Nut: 79 N·m (8.0 kgf·m, 58 ft·lb)
• 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.
FINAL DRIVE 9-5
Drive Chain
• Bend the cotter pin [A] over the nut [B].
the wheel, measure the chain slack again at the
• Rotate
tightest position, and readjust if necessary.
WARNING
If the axle nut is not securely tightened, or the cotter
pin is not installed, an unsafe riding condition may
result.
NOTE
○In wet and muddy conditions, mud sticks to the chain
and sprockets resulting in an overly tight chain, and the
chain may break. To prevent this, adjust the chain to 54
∼ 64 mm (KX65-A3 ∼, 55 ∼ 65 mm) of slack whenever
necessary.
Wheel Alignment Inspection
that the rear end [A] of the left chain adjuster [B]
• Check
aligns with the same swingarm mark [C] as the right chain
adjuster.
○Wheel
NOTE
alignment can also be checked using the
straightedge or string method.
WARNING
Misalignment of the wheel will result in abnormal
wear, and may result in an unsafe riding condition.
Wheel Alignment Adjustment
These procedures are the same as Drive Chain Slack Adjustment.
Drive Chain Wear Inspection
the rear wheel to inspect the drive chain for dam• Rotate
aged rollers, and loose pins and links.
[A] Bushing
[B] Roller
[C] Pin
[D] Pin Link
[E] Roller Link
If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
9-6 FINAL DRIVE
Drive Chain
the chain taut by hanging a 98 N (10 kg, 20 lb)
• Stretch
weight [A] on the chain.
the length of 20 links [B] on the straight part [C] of
• Measure
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 Length
Standard:
254.0 ∼ 254.6 mm
Service Limit: 259 mm
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
WARNING
If the drive chain wear exceeds the service limit, replace the chain or an unsafe riding condition may
result. A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control.
Standard Chain
Make:
DAIDO
Type:
DID 420MBK1
Link:
108 Links
110 Links (KX65-A3 ∼)
Drive Chain Lubrication
the chain appears especially dirty, it should be cleaned
• Ifbefore
lubrication with high flash-point solvent.
If
a
special
lubricant is not available, a heavy oil such as
• SAE90 is preferred
to a lighter oil because it will stay on
•
•
the chain longer and provide better lubrication.
Apply oil to the sides of the rollers so that oil will penetrate
to the rollers and bushings.
Oil Applied Areas [A]
Wipe off any excess oil.
Drive Chain Removal
the engine sprocket cover.
• Remove
the clip [A] from the master link using pliers, and
• Remove
free the drive chain from the rear sprocket.
• Remove the drive chain from the chassis.
FINAL DRIVE 9-7
Drive Chain
Drive Chain Installation
the drive chain back onto the sprockets with the ends
• Fit
at the rear sprocket.
the master link from the frame side.
• Install
Install
[A] so that the closed end of the "U" [B]
• points inthetheclipdirection
of chain rotation [C].
the drive chain slack (see Drive Chain Slack Ad• Adjust
justment).
• Check the rear brake (see the Brakes chapter).
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
the circlip with a new one.
• Replace
the circlip so that the tooth is aligned with a spline
• Install
groove.
Special Tool - Outside Circlip Pliers: 57001-144
Rear Sprocket Removal
• Remove the rear wheel (see Wheels/Tires chapter).
CAUTION
Do not lay the wheel on the ground with the disc
facing down. This can damage of warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
the rear sprocket bolts [A], and remove the rear
• Unscrew
sprocket [B].
Rear Sprocket Installation
the rear sprocket [A] so that the marked side [B]
• Install
faces out.
• Tighten the rear sprocket bolts.
Torque - Rear Sprocket Bolts: 26 N·m (2.7 kgf·m, 20 ft·lb)
Sprocket Wear Inspection
inspect the front and rear sprocket teeth.
• Visually
If the teeth are worn as illustrated, replace the sprocket,
and inspect the drive chain and engine sprocket (see
Drive Chain Wear Inspection).
Worn Tooth (Engine Sprocket) [A]
Worn Tooth (Rear Sprocket) [B]
Direction of Rotation [C]
CAUTION
If a sprocket requires replacement, the drive chain
is probably worn also. Upon replacing the rear
sprocket, inspect the chain and engine sprocket.
NOTE
○Sprocket wear is exaggerated for illustration.
FINAL DRIVE 9-9
Sprockets
Rear Sprocket Warp Inspection
• Using the jack, raise the rear wheel off the ground.
Special Tool - Jack: 57001-1238
a dial gauge [A] against the rear sprocket [B] near the
• Set
teeth as shown and rotate [C] the rear wheel to measure
the sprocket runout (warp). The difference between the
highest and lowest dial gauge readings is the amount of
runout (warp).
If the runout exceeds the service limit, replace the rear
sprocket.
Rear Sprocket Warp
Under 0.4 mm
Standard:
Service Limit: 0.5 mm
BRAKES 10-1
Brakes
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Brake Lever, Brake Pedal.......................................................................................................
Brake Lever Play Adjustment............................................................................................
Brake Pedal Position/Pedal Play Adjustment ...................................................................
Brake Pedal Removal .......................................................................................................
Brake Pedal Installation ....................................................................................................
Brake Fluid .............................................................................................................................
Fluid Level Inspection .......................................................................................................
Fluid Change.....................................................................................................................
Bleeding the Brake Line....................................................................................................
Caliper ....................................................................................................................................
Caliper Removal ...............................................................................................................
Caliper Installation ............................................................................................................
Caliper Disassembly .........................................................................................................
Caliper Assembly ..............................................................................................................
Fluid Seal Damage Inspection ..........................................................................................
Dust Seal and Cover Damage Inspection.........................................................................
Piston Cylinder Damage Inspection..................................................................................
Caliper Holder Shaft Wear Inspection...............................................................................
Brake Pad Removal ..........................................................................................................
Brake Pad Installation .......................................................................................................
Brake Pad Inspection........................................................................................................
Master Cylinder ......................................................................................................................
Front Master Cylinder Removal ........................................................................................
Front Master Cylinder Installation .....................................................................................
Rear Master Cylinder Removal.........................................................................................
Rear Master Cylinder Installation......................................................................................
Front Master Cylinder Disassembly ..................................................................................
Rear Master Cylinder Disassembly...................................................................................
Master Cylinder Assembly ................................................................................................
Master Cylinder Inspection (Visual Inspection).................................................................
Brake Disk ..............................................................................................................................
Brake Disc Inspection .......................................................................................................
Brake Hose.............................................................................................................................
Brake Hose Removal/Installation......................................................................................
Brake Hose Inspection......................................................................................................
10-2
10-4
10-5
10-5
10-5
10-5
10-6
10-7
10-8
10-8
10-10
10-12
10-12
10-12
10-13
10-13
10-14
10-14
10-14
10-14
10-15
10-15
10-15
10-16
10-16
10-16
10-17
10-17
10-17
10-18
10-18
10-19
10-20
10-20
10-21
10-21
10-21
10
10-2 BRAKES
Exploded View
1. Front Brake Reservoir
2. Brake Lever
3. Brake Hose
4. Clamps
5. Front Caliper
6. Brake Pad
7. Piston
8. Front Disc
T1: 25 N·m (2.5 kgf·m, 18 ft·lb)
T2: 8.8 N·m (0.90 kgf·m, 78 in·lb)
T3: 7.8 N·m (0.80 kgf·m, 69 in·lb)
T4: 18 N·m (1.8 kgf·m, 13 ft·lb)
T5: 9.8 N·m (1.0 kgf·m, 87 in·lb)
T6: 4.9 N·m (0.50 kgf·m, 43 in·lb)
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply Silicone grease.
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, 13 ft·lb)
G: Apply high temperature grease.
L: Apply a non-permanent locking agent.
R: Replacement Parts
Si: Apply Silicone grease.
10-4 BRAKES
Specifications
Item
Brake Adjustment
Lever Play
Brake Fluid
Recommended Disc Brake Fluid:
Type
Brake Pads
Lining Thickness:
Front
Rear
Brake Disc
Thickness:
Front
Rear
Runout
Standard
Service Limit
Adjustable (to suit rider)
– – –
DOT3 or DOT4
– – –
– – –
4.5 mm
4.5 mm
0.7 mm
0.7 mm
2.80 ∼ 3.20 mm
2.80 ∼ 3.20 mm
Not more than 0.15 mm
2.5 mm
2.5 mm
0.3 mm
Special Tools - Inside Circlip Pliers: 57001-143
Jack: 57001-1238
BRAKES 10-5
Brake Lever, Brake Pedal
Brake Lever Play Adjustment
the front brake lever [A] to suit you.
• Adjust
the brake lever dust cover [B] out of place.
• Slide
Loosen
adjuster locknut [C] and turn the adjuster [D]
• to eitherthe
side.
• After adjustment, tighten the locknut.
WARNING
Always maintain proper brake adjustment. If adjustment is improper, the brake could drag and
overheat. This could damage the brake assembly
and possibly lock the wheel resulting in loss of
control.
Brake Pedal Position/Pedal Play Adjustment
The brake pedal position and pedal play should not be
adjusted. There is no pedal position adjustment device
as such. The only adjustment is master cylinder push rod
length.
NOTE
○Usually it is not necessary to adjust the push rod length,
but always adjust it when the rear master cylinder [A] is
disassembled.
○When the brake pedal is in its rest position, measure
the length [B] indicated in the figure.
B: 80.5 mm
C: Push Rod Locknut
If the length is not within the specified length, adjust the
clevis [A] as follows.
○Loosen the push rod locknut [B].
○Pull out the cotter pin [C] and the joint pin [D].
○Turn the clevis to obtain the specified length.
○Tighten the locknut.
Torque - Push Rod Locknut: 18 N·m (1.8 kgf·m, 13 ft·lb)
○Install the joint pin and new cotter pin.
NOTE
○If the pedal position is incorrect after adjusting the master cylinder push rod, the brake pedal may be deformed
or incorrectly installed.
Brake Pedal Removal
• Remove:
Cotter Pin [A]
Joint Pin [B]
Washer
10-6 BRAKES
Brake Lever, Brake Pedal
the brake pedal mounting bolt [A] and take off
• Remove
the brake pedal and return spring [B].
Brake Pedal Installation
the pedal O-ring for signs of damage. If necessary,
• Check
replace them with new one.
high temperature grease to the shaft portion of the
• Apply
brake pedal, and install the pedal with return spring onto
the frame.
Torque - Brake Pedal Mounting Bolt: 25 N·m (2.5 kgf·m, 18
ft·lb)
the brake pedal position.
• Check
• Install the joint pin, washer and a new cotter pin.
BRAKES 10-7
Brake Fluid
WARNING
When working with the disc brake, observe the precautions 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 point
and could cause the brake to be ineffective. It may
also cause the rubber brake parts to deteriorate.
4. Don’t leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.
5. Don’t change the fluid in the rain or when a strong
wind is blowing.
6. Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that
no disc brake fluid or any oil gets on them. Clean off
any fluid or oil that inadvertently gets on the pads or
disc with a high flash-point solvent. Do not use one
which will leave an oily residue. Replace the pads
with new ones if they cannot be cleaned satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up immediately.
9. If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.
10-8 BRAKES
Brake Fluid
Fluid Level Inspection
In accordance with the Periodic Maintenance Chart, inspect 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 above the lower level
line [B]. If the fluid level in front reservoir is lower than
the lower level line, fill the reservoir to the upper level
line. Inside the front reservoir is stopped end showing
the upper level line [C].
rear reservoir [A] must be kept more than half full with
• The
brake fluid. If the amount of brake fluid is insufficient, add
brake fluid.
Fluid Change
In accordance with the Periodic Maintenance Chart,
change the brake fluid. The brake fluid should also be
changed if it becomes contaminated with dirt or water.
Furthermore, the brake fluid should be changed to bleed
the air quickly and completely whenever the brake line
parts are removed.
WARNING
Change the brake fluid in the brake line completely
if the brake fluid must be refilled but the type and
brand of the brake fluid that already is in the reservoir are unidentified. After changing the fluid, use
only the same type and brand of fluid thereafter.
Mixing different types and brand of brake fluid lowers the brake fluid boiling point and could cause the
brake to be ineffective. It may also cause the rubber
brake parts to deteriorate.
Recommended Disc Brake Fluid
Type:
DOT3 or DOT4
BRAKES 10-9
Brake Fluid
NOTE
○The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for
the front brake.
the brake fluid reservoir.
• Level
Remove
the reservoir cap.
• Remove the
cap [A] on the bleed valve [B].
• Attach a clearrubber
plastic
hose to the bleed valve on the
• caliper, and run the other
end of the hose into a container.
the brake fluid as follows:
•○Change
Repeat this operation until fresh brake fluid comes out
from the plastic hose or the color of the fluid changes.
Open the bleed valve [A]
Apply the brake and hold it [B]
Close the bleed valve [C]
Release the brake [D]
○Fill the reservoir with fresh specified brake fluid.
1.
2.
3.
4.
NOTE
○The fluid level must be checked often during the changing operation and replenished with fresh brake fluid. If
the fluid in the reservoir runs out any time during the
changing operation, the brakes will need to be bled
since air will have entered the brake line.
the clear plastic hose.
• Remove
Tighten
the
bleed valves, and install the rubber cap.
•
Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb)
changing the fluid, check the brake for good braking
• After
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines.
WARNING
Do not mix two brands of fluid. Change the brake
fluid in the brake line completely if the brake fluid
must be refilled but the type and brand of the brake
fluid that is already in the reservoir are unidentified.
NOTE
○Follow the procedure shown below to install the rear
brake fluid reservoir cap correctly. First, tighten the rear
brake reservoir cap [B] clockwise [C] by hand until slight
resistance is felt indicating that the cap is seated on the
reservoir body, then tighten the cap an additional 1/6
turn [D] while holding the brake fluid reservoir body [A].
10-10 BRAKES
Brake Fluid
Bleeding the Brake Line
The brake fluid has a very low compression coefficient so
that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.
WARNING
Be sure to bleed the air from the brake whenever
brake lever or pedal action feels soft or spongy, after the brake fluid is changed, or whenever a brake
line fitting has been loosened for any reason.
NOTE
○The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.
the reservoir cap, and check that there is plenty
• Remove
of fluid in the reservoir.
the reservoir cap off, slowly pump the brake lever
• With
several times until no air bubbles can be seen rising up
through the fluid from the holes at the bottom of the reservoir.
○Bleed the air completely from the master cylinder by this
operation.
Install the reservoir cap.
Attach a clear plastic hose to the bleed valve on the
caliper, and run the other end of the hose into a container.
Bleed the brake line and the caliper as follows:
○Repeat this operation until no more air can be seen coming out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply
the brake and hold it [A].
2. Quickly open and close the bleed valve while holding the
brake applied [B].
3. Release the brake [C].
•
•
•
NOTE
○The fluid level must be checked often during the bleed-
ing operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs almost out
any time during bleeding operation, the bleeding operation must be done over again from the beginning since
air will have entered the line.
○Tap the brake hose lightly from the caliper to the reservoir for easier bleeding.
BRAKES 10-11
Brake Fluid
the clear plastic hose.
• Remove
Tighten
the
bleed valves, and install the rubber cap.
•
Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb)
the fluid level.
• Check
bleeding is done, check the brake for good braking
• After
power, no brake drag, and no fluid leakage.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever or pedal is obtained by pumping the
brake lever or pedal until the pads are against the
disc. The brake will not function on the first application of the lever or pedal if this in not done.
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 is not available, remove the piston using
the following steps before disconnecting the brake hose
from the caliper.
○Remove the pads.
○Pump the brake lever to remove the piston.
•
•
•
•
Rear Brake
Unbolt the guard bolts and remove the rear caliper guard.
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 is not available, remove the piston using
the following steps before disconnecting the brake hose
from the caliper.
○Remove the pads.
○Pump the brake lever to remove the piston.
•
•
•
•
•
CAUTION
Immediately wipe up any brake fluid that is spilled.
Caliper Installation
• Tighten the brake pad bolts if they were removed.
Torque - Brake Pad Bolts: 18 N·m (1.8 kgf·m, 13 ft·lb)
the caliper, and the brake hose lower end.
•○Install
Replace the washers that are on each side of hose fitting
with new ones.
○Install the brake hose lower end so that the white paint
mark on it faces backward.
Torque - Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
the brake line (see Bleeding the Brake Line).
• Bleed
Check
brake for good braking power, no brake drag,
• and nothe
fluid leakage.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever or pedal is obtained by pumping the
brake lever or pedal until the pads are against the
disc. The brakes will not function on the first application of the lever or pedal if this is not done.
BRAKES 10-13
Caliper
Caliper Disassembly
the front/rear caliper (see Caliper removal).
• Remove
the pads and spring (see Pad Removal).
• Remove
Remove
• cover. the caliper holder, shaft rubber friction boot and
compressed air, remove the piston(s).
•○Using
Cover the caliper opening with a clean, heavy cloth [A].
○Remove the piston(s) by lightly applying compressed air
[B] to the hose joint opening.
WARNING
To avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply compressed air into the caliper, the piston(s) may crush
your hand or fingers.
NOTE
○If the caliper is to be disassembled after removal and
compressed air is not available, remove the piston(s)
using the following three steps before disconnecting the
brake hose from the caliper.
○Prepare a container for brake fluid, and perform the
work above it.
○Remove the pads and spring (see Pad Removal).
○Pump the brake lever or pedal to remove the caliper
piston(s).
the dust seal(s) and fluid seal(s).
• Remove
Remove
the bleed valve and rubber cap.
•
Caliper Assembly
• Clean the caliper parts except for the pads.
CAUTION
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
• Tighten the bleed valve with rubber cap.
Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb)
the fluid seal which is removed with new one.
•○Replace
Apply brake fluid to the fluid seal [B], and install it into the
cylinder by hand.
Replace the dust seal with new one if it is damaged.
○Apply brake fluid to the dust seal [A], and install it into the
cylinder by hand.
Apply brake fluid to the outside of the piston [C], and push
it into the cylinder by hand.
•
•
10-14 BRAKES
Caliper
• Install the anti-rattle spring [A] in the caliper as shown.
the shaft rubber boot and dust cover if they are
• Replace
damaged.
a thin coat of silicone grease to the caliper holder
• Apply
shafts and holder holes (PBC is a special high tempera-
•
•
ture, water-resistant grease).
Install the pads (see Pads Installation).
Wipe up any spilled brake fluid on the caliper.
Fluid Seal Damage Inspection
The fluid seal around the piston maintains the proper
pad/disc clearance. If this seal is not in good condition,
pad wear will increase, and constant pad drag on the disc
will raise brake and brake fluid temperature.
Replace the fluid seals under any of the following conditions: (a) fluid leakage around the pad; (b) brakes overheat; (c) there is a large difference in left and right pad
wear; (d) the seal is stuck to the piston. If the fluid seal is
replaced, replace the dust seal as well. Also, replace all
seals every other time the pads are changed.
•
Dust Seal and Cover Damage Inspection
that the dust seals and covers are not cracked,
• Check
worn, swollen, or otherwise damaged.
If they show any damage, replace them.
Piston Cylinder Damage Inspection
inspect the piston and cylinder surfaces.
• Visually
Replace the cylinder and piston if they are badly scored
or rusty.
Caliper Holder Shaft Wear Inspection
The caliper body must slide smoothly on the caliper holder
shafts. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.
Check to see if the caliper holder shafts are not badly worn
or stepped, or the rubber boot is not damaged.
If the shafts or rubber boot are damaged, replace the
shafts, rubber boot, and the caliper holder.
•
BRAKES 10-15
Caliper
Brake Pad Removal
the pad bolts [A].
• Loosen
the caliper [B].
• Remove
Remove
pad bolts.
• Take out the
the
piston side pad.
• Push the caliper
toward the piston, and then re• move another padholder
from the caliper holder.
Brake Pad Installation
the caliper pistons in by hand as far as they will go.
• Push
the piston side pad [A] first, and then another pad
• Install
[B].
• Tighten the brake pad bolt.
Torque - Brake Pad Bolts: 18 N·m (1.8 kgf·m, 13 ft·lb)
the brake for good braking power, no brake drag,
• Check
and no fluid leakage.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever or pedal is obtained by pumping the
brake lever or pedal until the pads are against the
disc. The brake will not function on the first application of the lever or pedal if this is not done.
Brake Pad Inspection
the lining thickness and condition of the pads in
• Check
each caliper.
If either pad is damaged, replace both pads in the caliper
as a set.
If the lining thickness [A] of either pad is less than the
service limit [B], replace both pads in the caliper as a set.
Lining Thickness
Standard:
Front
4.5 mm
Rear
4.5 mm
Service Limit:
Front
0.7 mm
Rear
0.7 mm
10-16 BRAKES
Master Cylinder
CAUTION
Brake fluid quickly ruins painted or plastic surfaces; any spilled fluid should be completely wiped
up immediately.
Front Master Cylinder Removal
the banjo bolt [A] to disconnect the upper brake
• Remove
hose from the master cylinder (see Brake Hose Re-
•
•
moval/Installation).
When removing the brake hose, temporarily secure the
end of the brake hose to some high place to keep fluid
loss to a minimum.
Unscrew the master cylinder clamp bolts [B], and take off
the master cylinder [C] as an assembly with the reservoir
and brake lever.
Front Master Cylinder Installation
the master cylinder so that the parting line [A] of
• Position
the master cylinder clamp align with the punch mark [B]
on the handlebar.
master cylinder clamp must be installed with the ar• The
row mark [A] upward.
○Tighten the upper clamp bolt [B] first, and then the lower
clamp bolt [C] There will be a gap at the lower part of the
clamp after tightening.
Torque - Master Cylinder Clamp Bolts: 8.8 N·m (0.9 kgf·m,
78 in·lb)
the washers that are on each side of hose fitting
• Replace
with new ones.
• Tighten the brake hose banjo bolt.
Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
the brake line (see Bleeding the Brake Line).
• Bleed
the brake for good braking power, no brake drag,
• Check
and no fluid leakage.
BRAKES 10-17
Master Cylinder
Rear Master Cylinder Removal
the right side cover and the reservoir mounting
• Remove
bolt [A].
the cotter pin [B].
• Remove
Pull
off
the
joint pin [C] with washer.
•
○Pull
NOTE
off the joint pin while pressing down the brake
pedal.
the brake hose banjo bolt [D] (see Brake Hose
• Unscrew
Removal/Installation).
removing the brake hose, temporarily secure the
• When
end of the brake hose to some high place to keep fluid
•
•
•
loss to a minimum.
Unscrew the master cylinder mounting bolts [E], and remove the master cylinder [F] with the reservoir.
Remove the reservoir cap, and pour the brake fluid into a
container.
Remove the reservoir and its hose from the master cylinder.
Rear Master Cylinder Installation
the cotter pin with a new one.
• Replace
Replace
the
• new ones. washers are on each side of hose fitting with
• Tighten the following:
Torque - Master Cylinder Mounting Screws: 9.8 N·m (1.0
kgf·m, 87 in·lb)
Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
the brake line (see Bleeding the Brake Line).
• Bleed
the brake for good braking power, no brake drag,
• Check
and no fluid leakage.
the brake pedal position (master cylinder push rod
• Check
length).
Front Master Cylinder Disassembly
the front master cylinder.
• Remove
Remove
cap and diaphragm, and pour the
• brake fluidtheintoreservoir
a container.
Unscrew
the
locknut
and pivot bolt, and remove the brake
• lever.
the dust cover [A] out of place, and remove the cir• Push
clip [B].
Special Tool - Inside Circlip Pliers: 57001-143
the washer [C], pull out the piston [D], primary
• Remove
cup [F], and return spring [G].
CAUTION
Do not remove the secondary cup [E] from the piston since removal will damage it.
10-18 BRAKES
Master Cylinder
Rear Master Cylinder Disassembly
the rear master cylinder.
• Remove
the dust cover [A] on the push rod [B] out of place,
• Slide
and remove the retainer [C].
Special Tool - Inside Circlip Pliers: 57001-143
out the push rod with the piston stop [D].
• Pull
Take
• [H]. off the piston [E], primary cup [G], and return spring
CAUTION
Do not remove the secondary cup [F] from the piston since removal will damage it.
the circlip [I], and take off the connector [J] and
• Remove
O-ring [K].
Master Cylinder Assembly
assembly, clean all parts including the master
• Before
cylinder with brake fluid or alcohol.
brake fluid to the removed parts and to the inner
• Apply
wall of the cylinder.
CAUTION
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.
care not to scratch the piston or the inner wall of the
• Take
cylinder.
• Tighten the brake lever pivot bolt and the locknut securely.
Torque - Rear Master Cylinder Push Rod Locknut: 18 N·m
(1.8 kgf·m, 13 ft·lb)
BRAKES 10-19
Master Cylinder
Master Cylinder Inspection (Visual Inspection)
the front and rear master cylinders.
• Disassemble
that there are no scratches, rust or pitting on the
• Check
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 primary [C] and secondary [D] cups.
If a cup is worn, damaged, softened (rotted), or swollen,
the piston assembly should be replace to renew the cups.
If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cup.
Check the dust covers [E] for damage.
If they are damaged, replace them.
Check that the relief [G] and supply [H] ports are not
plugged.
If the small relief port becomes plugged, the brake pads
will drag on the disc. Blow the ports clean with compressed air.
Check the piston return springs [F] for any damage.
If a spring is damaged, replace it.
[J] Front Master Cylinder
[K] Rear Master Cylinder
10-20 BRAKES
Brake Disk
Brake Disc Inspection
inspect the disc [A].
• Visually
If it is scratched or damaged, replace the disc.
the thickness of each disc at the point [B] where
• Measure
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 Limit:
Front
2.5 mm
Rear
2.5 mm
Torque - Brake Disc Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87
in·lb)
a jack under the motorcycle so that the front/rear
• Place
wheel is raised off the ground.
Special Tool - Jack: 57001-1238
up a dial gauge against the disc [A] as illustrated.
•○Set
For the front disc, turn the handlebar fully to one side.
the disc runout while rotating the wheel slowly
• Measure
[B].
If the runout exceeds the service limit, replace the disc.
Runout
Standard:
Not more than 0.15 mm
Service Limit: 0.3 mm
BRAKES 10-21
Brake Hose
Brake Hose Removal/Installation
CAUTION
Brake fluid quickly ruins painted or plastic surfaces; any spilled fluid should be completely wiped
up immediately with watered cloth.
removing the brake hose, take care not to spill the
• When
brake fluid on the painted or plastic parts.
removing the brake hose, temporarily secure the
• When
end of the brake hose to some high place to keep fluid
•
•
•
loss to a minimum.
There are washers on each side of the brake hose fitting.
Replace them with new ones when installing.
When installing the hoses, avoid sharp bending, kinking,
flattening or twisting, and route the hoses according to
the Cable, Wire and Hose Routing section in the General
Information chapter.
Torque the banjo bolts at the hose fittings.
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
the brake line after installing the brake hose (see
• Bleed
Bleeding the Brake Line).
Brake Hose Inspection
high pressure inside the brake line can cause fluid to
• The
leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining
it.
Replace it if any cracks [B] or bulges [C] are noticed
SUSPENSION 11-1
Suspension
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Front Fork ...............................................................................................................................
Rebound Damping Adjustment (KX65-A3 ∼) ....................................................................
Fork Oil Level Adjustment (Simplify).................................................................................
Oil Change/Oil Level Adjustment (each fork leg) ..............................................................
Front Fork Removal ..........................................................................................................
Front Fork Installation .......................................................................................................
Front Fork Disassembly (each fork)..................................................................................
Front Fork Assembly (each fork).......................................................................................
Inner Tube Inspection .......................................................................................................
Guide Bush Inspection......................................................................................................
Dust Seal/Oil Seal Inspection ...........................................................................................
Spring Tension Inspection.................................................................................................
Rear Suspension (Uni-Trak)...................................................................................................
Rear Shock Absorber ..........................................................................................................
Rebound Damping Force Adjustment...............................................................................
Spring Preload Adjustment ...............................................................................................
Rear Shock Absorber Removal ........................................................................................
Rear Shock Absorber Installation .....................................................................................
Spring Replacement .........................................................................................................
Spring Tension ..................................................................................................................
Rear Shock Absorber Scrapping ......................................................................................
Swingarm................................................................................................................................
Swingarm Removal...........................................................................................................
Swingarm Installation........................................................................................................
Swingarm Bearing Removal .............................................................................................
Swingarm Bearing Installation ..........................................................................................
Tie-rod, Rocker Arm ...............................................................................................................
Tie-rod Removal ...............................................................................................................
Tie-rod Installation ............................................................................................................
Rocker Arm Removal........................................................................................................
Rocker Arm Installation.....................................................................................................
Needle Bearing Inspection................................................................................................
Uni-Trak Maintenance ............................................................................................................
Rocker Arm Sleeve Wear Inspection ................................................................................
Rocker Arm Mounting Bolt Bend Inspection .....................................................................
11-2
11-6
11-7
11-7
11-7
11-9
11-10
11-11
11-11
11-13
11-14
11-14
11-14
11-14
11-15
11-15
11-15
11-15
11-16
11-17
11-17
11-18
11-18
11-19
11-19
11-19
11-19
11-20
11-21
11-21
11-21
11-21
11-22
11-22
11-23
11-23
11-23
11
11-2 SUSPENSION
Exploded View
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 (2.2 kgf·m, 16 ft·lb)
T2: 20 N·m (2.0 kgf·m, 14 ft·lb)
T3: 29 N·m (3.0 kgf·m, 22 ft·lb)
T4: 44 N·m (4.5 kgf·m, 33 ft·lb)
L: Apply a non-permanent locking agent.
11-4 SUSPENSION
Exploded View
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 ft·lb)
G: Apply grease.
L: Apply a non-permanent locking agent.
11-6 SUSPENSION
Specifications
Item
Front Fork
Oil
Oil Capacity (Completely Dry)
Oil Level (Fully Compressed,
Spring Removed)
Fork Spring Free Length
Rear Suspension (Uni-Trak)
Rear Shock Absorber
Spring Preload Adjustment
(Adjusting nut position from the
center of the upper mounting hole)
Rear Shock Spring Free Length
Standard
SHOWA SS-8 or equivalent
238 ±2.5 mL (KX65-A1)
240 ±2.5 mL (KX65-A2)
252 ±2.5 mL (KX65-A3 ∼)
124 ±2 mm (KX65-A1)
(from top of inner tube)
126 ±2 mm (KX65-A2)
(from top of inner tube)
132 ±2 mm (KX65-A3 ∼)
(from top of inner tube)
455.7 mm (KX65-A1)
470.7 mm (KX65-A2)
497.1 mm (KX65-A3 ∼)
88.8 mm (KX65-A1)
86.6 mm (KX65-A2)
79.6 mm (KX65-A3 ∼)
206.1 mm
211.1 mm (KX65-A3 ∼)
Gas Reservoir
Gas Pressure
980 kPa (10 kgf/cm², 142 psi)
Tie-rod, Rocker Arm
17.989 ∼ 18.000 mm
Sleeve Outside Diameter
Rocker Arm Mounting Bolt Runout under 0.1 mm
Special Tools - Fork Cylinder Holder Handle: 57001-183
Fork Cylinder Holder Adapter: 57001-1011
Oil Seal & Bearing Remover: 57001-1058
Hook Wrench: 57001-1101
Bearing Driver Set: 57001-1129
Fork Outer Tube Weight: 57001-1218
Fork Oil Seal Driver: 57001-1219
Jack: 57001-1238
Fork Oil Level Gauge: 57001-1290
Service Limit
– – –
– – –
– – –
– – –
98 ∼ 140 mm (KX65-A1)
96 ∼ 139 mm (KX65-A2)
98 ∼ 142 mm (KX65-A3 ∼)
446.6 mm (KX65-A1)
461.3 mm (KX65-A2)
487.2 mm (KX65-A3 ∼)
(Adjustable Range)
82.8 ∼ 94.8 mm
75.6 ∼ 83.6 mm
202.0 mm
206.9 mm (KX65-A3 ∼)
– – –
17.96 mm
0.2 mm
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 level (more oil ) will make the fork repulsion
more large. A lower oil level (less oil) will make the fork
repulsion more small.
○Fork springs - Optional springs are available that are
softer and stiffer than standard.
○Fork clamp position - Steering qualities are greatly affected by the fork clamp position. Fork tube height is
the amount of the inner tube projecting above the steering stem head. When the fork tube height is smaller, the
front end becomes lighter due to the change in weight
bias. Also, it tends to understeer in turns and “wash out”.
When the height is greater, the results are opposite.
Rebound Damping Adjustment (KX65-A3 ∼)
adjust rebound damping, turn the adjuster [A] on the
• To
front fork top plugs with the blade of a screwdriver until
you feel a click. Adjust the rebound damping to suit you
preference under special condition.
CAUTION
The left and right fork legs must have the same
shock damping.
Seated positions: adjuster turned fully clockwise [A].
Rebound Damping Adjuster Setting
3 clicks
Standard:
Fork Oil Level Adjustment (Simplify)
• Raise the front wheel off the ground using a jack.
Special Tool - Jack: 57001-1238
the number plate.
• Remove
Remove
the
front fork top plugs [A] and the fork spring [B].
•
11-8 SUSPENSION
Front Fork
KX65-A3 ∼
Remove:
Number Plate
Handlebar Assembly
Front Fork Top Plug [A]
Fork Spring [B]
Fork Spring Seat [C]
•
compress the front fork fully by pushing up the
• Slowly
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.
the oil level gauge to measure the fork oil level.
•○Use
With the fork fully compressed, put the oil level gauge [A]
and the stopper [B], and adjust the distance from the top
of the inner tube to oil.
Special Tool - Fork Oil Level Gauge: 57001-1290
Front Fork Oil Level (fully compressed, without spring)
Standard:
124 ±2 mm (KX65-A1)
126 ±2 mm (KX65-A2)
132 ±2 mm (KX65-A3 ∼)
Adjustable Range:
98 ∼ 140 mm (KX65-A1)
96 ∼ 139 mm (KX65-A2)
98 ∼ 142 mm (KX65-A3 ∼)
If no oil is drawn out, there is insufficient oil in the fork
tube. Pour in enough oil, then pump out the excess oil.
Fork Oil:
SHOWA SS-8 or equivalent
the both diameters of the fork spring ends and
• Measure
insert the fork spring with the small diameter end [A] facing down.
SUSPENSION 11-9
Front Fork
both top plug O-ring [A] for damage and replace
• Check
them if necessary.
the fork top plug.
• Install
Install
the
and fork spring seat (KX65-A3 ∼).
• Tighten theforkforktoptopplug
plug.
•
Torque - Front Fork Top Plug: 22 N·m (2.2 kgf·m, 16 ft·lb)
the other fork tube in the same way as de• Assemble
scribed above.
the parts removed.
• Install
Install
the
• KX65-A3 ∼handlebar assembly (see Steering). :
Oil Change/Oil Level Adjustment (each fork leg)
the front fork (see this chapter).
• Remove
Remove
• Top Plugthe following.
Fork Spring
Fork Spring Seat (KX65-A3 ∼)
WARNING
The top plugs are under extreme spring force. Take
care when removing the top plugs. Wear eye and
face protection.
the fork tube upside down over a clean container
• Hold
and pump it to drain the oil.
• Fill the front fork to the top with specified oil.
Recommended Oil
SHOWA SS-8 or equivalent
Front Fork Oil Capacity (completely dry)
238 ±2.5 mL (KX65-A1)
240 ±2.5 mL (KX65-A2)
252 ±2.5 mL (KX65-A3 ∼)
11-10 SUSPENSION
Front Fork
the oil level.
•○Adjust
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)
Standard:
124 ±2 mm (KX65-A1)
126 ±2 mm (KX65-A2)
132 ±2 mm (KX65-A3 ∼)
Adjustable Range:
98 ∼ 140 mm (KX65-A1)
96 ∼ 139 mm (KX65-A2)
98 ∼ 142 mm (KX65-A3 ∼)
•
If no oil is drawn out, there is insufficient oil in the fork
tube. Pour in enough oil, then drawn out the excess oil.
Install the parts removed (see Front Fork Assembly)
Front Fork Removal
the front brake hose clamps [A].
• Remove
Remove
the caliper [B] from the fork leg to be removed,
• and rest the
caliper on some kind of stand so that it doesn’t
•
dangle.
Remove the front wheel (see Wheels/Tires chapter).
the number plate.
• Remove
Loosen
the
upper and lower fork clamp bolts [A].
• With a twisting
motion, work the fork leg down and out.
•
SUSPENSION 11-11
Front Fork
Front Fork Installation
the fork leg was disassembled, check the fork oil level.
• IfInstall
so that the top end [A] of the inner tube is
• 10 mmtheupfork
[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 surface [C] of the steering
stem head (KX65-A3 ∼).
Route the cables and hose according to the Cable, Wire
and Hose Routing section in the General Information
chapter.
Install the front wheel (see Wheels/Tires chapter).
Tighten the following:
Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0
kgf·m, 14 ft·lb)
Front Fork Clamp Bolts (Lower): 29 N·m (3.0
kgf·m, 22 ft·lb)
Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
• Check the front brake operation after installation.
Front Fork Disassembly (each fork)
the front fork (see this chapter).
• Remove
Remove
the
and the fork spring.
• Drain the forktopoil plug
with
the fork upside down (see Fork Oil
• Change)
the outer tube [A] in a vise.
• Hold
Stop
the cylinder [B] from turning by using the front fork
• cylinder
holder.
Special Tools - Fork Cylinder Holder Handle: 57001-183 [C]
Fork Cylinder Holder Adapter: 57001-1011
[D]
the Allen bolt [E], then take the bolt and gasket
• Unscrew
out of the bottom of the outer tube.
KX65-A3 ∼
Loosen the top plug.
Remove the front fork (see this chapter).
Hold the outer tube [A] in a vise.
Hold of the inner tube [B] and loosen the Allen bolt [C].
Remove the top plug, the fork spring seat and fork spring
(see Fork Oil Level Adjustment).
Drain the fork oil with the fork upside down (see Fork Oil
Change)
Take out the Allen bolt [C] and gasket.
•
•
•
•
•
•
•
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].
the fork outer tube weight [A] to separate the inner
• Use
tube from the outer tube.
Special Tool - Fork Outer Tube Weight: 57001-1218
○Holding the inner tube by hand in a vertical position, pull
down the outer tube several times to pull out the inner
tube.
○The oil seal [A], washer [B], and guide bushes [C] come
off with the inner tube.
○Take the cylinder base out of the outer tube.
SUSPENSION 11-13
Front Fork
Front Fork Assembly (each fork)
is the reverse of disassembly.
• Assembly
the following parts removed with a new one.
• Replace
Guide Bushes
Oil Seal
Bottom Allen Bolt Gasket
Inspect the following and replace them with new ones if
damaged.
Inner Tube (see Inner Tube Inspection)
Top Plug O-ring
Insert the cylinder unit and spring in the inner tube.
Insert the cylinder base [A] in the cylinder unit [B].
○The cylinder base must be installed with the tapered side
facing upward.
Install the cylinder unit in the inner tube and the cylinder
base in the bottom of the outer tube.
•
•
•
•
a non-permanent locking agent to the bottom Allen
• Apply
bolt and tighten it to the specified torque, using the front
fork cylinder holder.
Torque - Fork Bottom Allen Bolts: 20 N·m (2.0 kgf·m, 14
ft·lb)
Special Tools - Fork Cylinder Holder Handle: 57001-183
(use for KX65-A1 ∼ A2)
Fork Cylinder Holder Adapter: 57001-1011
(use for KX65-A1 ∼ A2)
the guide bush [A] (with a used guide bush [B] on
• Install
it) by tapping [C] the used guide bush with the fork oil seal
driver [D] until it stops.
Special Tool - Fork Oil Seal Driver: 57001-1219
the following.
• Install
Washer
Oil Seal (use the fork oil seal driver: 57001-1219, the
marked side upward)
Retaining Ring
Dust Seal
the both diameters of the fork spring ends and
• Measure
insert the fork spring with the small diameter [A] facing
•
•
down.
Pour the fork oil (see Fork Oil change).
Install the front fork (see Front Fork Installation).
11-14 SUSPENSION
Front Fork
Inner Tube Inspection
inspect the inner tube [A], repair any damage.
• Visually
or rust damage can sometimes be repaired by using
• Nick
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 seal,
replace the oil seal whenever the inner tube is repaired
or replaced.
Temporarily assemble the inner and outer tubes, and
pump them back and forth manually to check for smooth
operation.
CAUTION
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
Guide Bush Inspection
inspect the guide bushes [A], and replace them if
• Visually
necessary.
Dust Seal/Oil Seal Inspection
the dust seal [A] for any signs of deterioration or
• Inspect
damage.
•
Replace it if necessary.
Replace the oil seal [B] with a new one whenever it has
been removed.
Spring Tension Inspection
a spring becomes shorter as it weakens, check its
• Since
free length [A] to determine it condition.
If the spring of either fork leg is shorter than the service
limit, it must be replaced. If the length of a replacement
spring and that of the remaining spring vary greatly, the
remaining spring should also be replaced in order to keep
the fork legs balanced fro motorcycle stability.
Fork Spring Free Length
Standard:
455.7 mm (KX65-A1)
470.7 mm (KX65-A2)
497.1 mm (KX65-A3 ∼)
Service Limit:
446.6 mm (KX65-A1)
461.3 mm (KX65-A2)
487.2 mm (KX65-A3 ∼)
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 spring can be
replaced with an optional one.
KX65-A3 ∼
The damping force can be adjusted easily so changing oil
viscosity unnecessary.
Rebound Damping Force Adjustment
adjust the rebound damping force,
• To
damping adjuster [A] punch mark [B].
turn the lower
If the damping feels too soft or too stiff, adjust it.
Seated position: adjuster tuned fully clockwise [A]
Rebound Damping Adjuster Setting
Standard:
1 1/2 turns out
○Differ the individually for shock absorber side of the punch
mark position [B].
Spring Preload Adjustment
• Remove:
Seat
•
Side Covers
Rear Frame [A]
Air Cleaner Housing [B]
Using the jack under the frame, raise the rear wheel off
the ground.
Special Tool - Jack: 57001-1238
the hook wrenches [A], loosen the locknut [B] on
• Using
the rear shock absorber.
Special Tool - Hook Wrench: 57001-1101
11-16 SUSPENSION
Rear Suspension (Uni-Trak)
the hook wrench [A], turn the adjusting nut [B] as
• Using
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 center
of the mounting hole)
Standard:
88.8 mm (KX65-A1)
86.6 mm (KX65-A2)
79.6 mm (KX65-A3 ∼)
Adjustable Range:
82.8 ∼ 94.8 mm (KX65-A1 ∼ A2)
75.6 ∼ 83.6 mm (KX65-A3 ∼)
the locknut securely.
• Tighten
After
adjusting,
move the spring up and down to make
• sure that the spring
is seated.
Install
the
parts
removed.
• Tighten the rear frame mounting bolts.
•
Torque - Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m 25
ft·lb)
Rear Shock Absorber Removal
• Remove:
Seat
•
Side Covers
Rear Frame
Air Cleaner Housing
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].
CAUTION
When pulling out the mounting bolts, lift the rear
wheel slightly. Forcing or tapping on a bolt could
damage the bolt, sleeve, and bearing
• Remove the rear shock absorber mounting bolt B].
SUSPENSION 11-17
Rear Suspension (Uni-Trak)
the rear shock absorber upper mounting bolt [A],
• Remove
and pull out the rear shock absorber [B].
Rear Shock Absorber Installation
the rocker arm needle bearings with grease.
• Pack
• Tighten the following:
Torque - Rear Shock Absorber Mounting Bolt (Upper): 39
N·m (4.0 kgf·m, 29 ft·lb)
Rear Shock Absorber Mounting Nut (Lower): 34
N·m (3.5 kgf·m, 25 ft·lb)
Tie-rod Mounting Nut: 59 N·m (6.0 kgf·m, 43 ft·lb)
Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
Spring Replacement
In addition to the standard spring, heavy and light springs
are available. If the standard spring is improper for your
purpose, select a proper one according to the rider’s weight
or course conditions.
Remove
Side Covers
Seat
Rear Frame
Air Cleaner Housing
Remove the rear shock absorber.
Clean the threaded portion on the upper of the rear shock
absorber.
Hold the lower of the rear shock absorber with a vise.
•
•
•
•
the hook wrenches [C], loosen the locknut [B] and
• Using
turn the adjusting nut [A] all way up.
Special Tool - Hook Wrench: 57001-1101
11-18 SUSPENSION
Rear Suspension (Uni-Trak)
the rear shock absorber from the vise.
• Remove
Remove
the stopper ring [A].
• Remove the
spring seat [B] from the shock absorber and
• lift off the spring
[C].
the spring guide.
• Install
Adjust
• ment). the spring preload (see Spring Preload Adjustthe rear shock absorber.
• Install
Install
the parts removed.
•
Spring Tension
Since a spring becomes shorter as it weakens, check its
free length [A] to determine its condition.
If the spring is shorter than the service limit, it must be
replaced.
Rear Shock Absorber Spring Free Length
Standard:
206.1 mm (KX65-A1 ∼ A2)
211.1 mm (KX65-A3 ∼)
Service Limit: 202.0 mm (KX65-A1 ∼ A2)
206.9 mm (KX65-A3 ∼)
Rear Shock Absorber Scrapping
WARNING
Since the reservoir tank of the rear shock absorber
contains nitrogen gas, do not incinerate the reservoir tank without first releasing the gas or it may
explode.
the shock absorber (see Rear Shock Absorber
• Remove
Removal).
the valve cap [A] and release the nitrogen gas
• Remove
completely from the gas reservoir.
• Remove the valve.
WARNING
Since the high pressure gas is dangerous, do not
point the valve toward your face or body.
SUSPENSION 11-19
Swingarm
Swingarm Removal
the jack under the frame so that the rear wheel is
• Place
off the ground.
Special Tool - Jack: 57001-1238
the rear wheel (see Wheels/Tires chapter).
• Remove
Remove
the brake pedal [A].
• Remove the
tie-rod rear mounting bolt [B].
•
CAUTION
When pulling out the mounting bolts, lift the rear
wheel slightly. Forcing or tapping on a bolt could
damage the bolt, sleeve, and bearing.
out the swingarm pivot shaft [C], and remove the
• Pull
swingarm [D].
the chain guide and chain slipper from the
• Separate
swingarm.
Swingarm Installation
plenty of grease to the inside of the needle bear• Apply
ings, sleeves, and oil seals caps.
• Tighten the following:
Torque - Swingarm Pivot Shaft Nut: 69 N·m (7.0 kgf·m, 51
ft·lb)
Tie-rod Mounting Nut: 59 N·m (6.0 kgf·m, 43 ft·lb)
to the Wheels/Tires, Final Drive, and Brakes chap• Refer
ters for wheel installing.
Swingarm Bearing Removal
• Remove:
Swingarm
•
Dust Seals [A]
Oil Seals [B]
Sleeves [C]
Remove the needle bearings [D] using the bearing remover.
Special Tool - Oil Seal & Bearing Remover: 57001-1058
11-20 SUSPENSION
Swingarm
Swingarm Bearing Installation
the needle bearings, dust seals and oil seals with
• Replace
new ones.
plenty of grease to the dust seals, oil seals and
• Apply
needle bearings.
NOTE
○Install the needle bearings so that the manufacturer’s
marks face out.
Special Tool - Bearing Driver Set: 57001-1129
the needle bearings [A] dust seals [B] and oil seals
• Install
[C] position as shown.
○The
side.
installation procedure is the same as the counter
SUSPENSION 11-21
Tie-rod, Rocker Arm
Tie-rod Removal
the jack under the frame, raise the rear wheel off
• Using
the ground.
Special Tool - Jack: 57001-1238
• Remove the tie-rod front mounting bolt [A].
CAUTION
When pulling out the mounting bolts, lift the rear
wheel slightly. Forcing or tapping on a bolt could
damage the bolt, sleeve, and bearing.
the tie-rod rear mounting bolt [B], and then take
• Remove
out the tie-rods [C].
Tie-rod Installation
plenty of grease to the inside of the needle bearings
• Apply
and oil seals.
• Tighten the tie-rod front and rear mounting nuts.
Torque - Tie-rod Mounting Nuts: 59 N·m (6.0 kgf·m, 43 ft·lb)
Rocker Arm Removal
the jack under the frame, raise the rear wheel off
• Using
the ground.
Special Tool - Jack: 57001-1238
• Remove the chain [A] and the lower chain guide roller [B].
• Remove the tie-rod front mounting bolt [A].
CAUTION
When pulling out the mounting bolts, lift the rear
wheel slightly. Forcing or tapping on bolt could
damage the bolt, sleeve, and bearing.
the rear shock absorber lower mounting bolt [B].
• Remove
Remove
rocker arm pivot shaft [C].
• Remove the
the
rocker arm [D].
•
11-22 SUSPENSION
Tie-rod, Rocker Arm
Rocker Arm Installation
plenty of grease to the inside of the rocker arm
• Apply
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 following:
Torque - Rocker Arm Pivot Nut: 83 N·m (8.5 kgf·m, 61 ft·lb)
Rear Shock Absorber Mounting Nut (Lower): 34
N·m (3.5 kgf·m, 25 ft·lb)
Tie-rod Mounting Nuts: 59 N·m (6.0 kgf·m, 43 ft·lb)
Swingarm Pivot Shaft Nut: 69 N·m (7.0 kgf·m, 51
ft·lb)
Needle Bearing Inspection
If there is any doubt as to the condition of either needle
bearing, replace the bearing and sleeve as a set.
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
and pull on the swingarm [A], up and down, to check
• Push
for wear.
A small amount of play on the swingarm is normal and no
corrective action is needed. However, if excessive play is
felt, remove the uni-trak parts from the frame and check
for wear.
Rocker Arm Sleeve Wear Inspection
out the sleeves [A] of the rocker arm, and measure
• Pull
the outside diameter of the sleeve.
If the sleeve is worn past the service limit, replace the
sleeve.
Sleeve Outside Diameter
17.989 ∼ 18.000 mm
Standard:
Service Limit: 17.96 mm
Rocker Arm Mounting Bolt Bend Inspection
A bent bolt causes vibration, poor handling, and instability.
To measure the bolt runout, remove the bolt, place it
in V block, and set a dial gauge to the bolt at a point
halfway between the block. Turn [A] the bolt to measure
the runout. The amount of dial variation is the amount of
runout.
If runout exceeds the service limit, replace the bolt.
•
Bolt Runout
Standard:
Under 0.1 mm
Service Limit: 0.2 mm
STEERING 12-1
Steering
Table of Contents
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Steering ..................................................................................................................................
Steering Inspection ...........................................................................................................
Steering Adjustment..........................................................................................................
Steering Stem, Stem Bearing Removal ............................................................................
Steering Stem, Stem Bearing Installation .........................................................................
Steering Maintenance.............................................................................................................
Stem Bearing Lubrication..................................................................................................
Stem Bearing Wear, Damage Inspection..........................................................................
Stem Warp Inspection.......................................................................................................
Handlebar ...............................................................................................................................
Handlebar Removal ..........................................................................................................
Handlebar Installation .......................................................................................................
Clutch Lever Installation....................................................................................................
12-2
12-3
12-4
12-4
12-4
12-5
12-6
12-8
12-8
12-8
12-8
12-9
12-9
12-9
12-9
12
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 (0.30 kgf·m, 26 in·lb)
T4: 25 N·m (2.5 kgf·m, 18 ft·lb)
T5: 29 N·m (3.0 kgf·m, 22 ft·lb)
T6: 8.8 N·m (0.90 kgf·m, 78 in·lb)
AD: Apply adhesive cement.
G: Apply grease.
STEERING 12-3
Specifications
Special Tools - Steering Stem Bearing Driver: 57001-137
Head Pipe Outer Race Press Shaft: 57001-1075
Steering Stem Bearing Driver Adapter: 57001-1092
Steering Stem Nut Wrench: 57001-1100
Head Pipe Outer Race Driver: 57001-1106
Head Pipe Outer Race Remover: 57001-1107
Jack: 57001-1238
12-4 STEERING
Steering
Steering Inspection
• Using the jack, raise the front wheel off the ground.
Special Tool - Jack: 57001-1238
the front wheel pointing straight ahead, alternately
• With
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 steering binds or catches before the stop, check the
routing of the cables, hoses, and harnesses.
If the steering feels tight, adjust or lubricate the steering.
Feel for steering looseness by pushing and pulling the
forks.
If you feel looseness, adjust the steering.
Steering Adjustment
the number plate.
• Remove
Using
the
jack, raise the front wheel off the ground.
•
Special Tool - Jack: 57001-1238
the handlebar.
• Remove
the front fork clamp bolts [A] and steering stem
• Loosen
head nut [B].
the steering stem nut [A] with the steering stem nut
• Turn
wrench [B] to obtain the proper adjustment.
If the steering is too tight, loosen the steering stem nut a
fraction of a turn; if the steering is too loose, tighten the
nut a fraction of a turn.
Special Tool - Steering Stem Nut Wrench: 57001-1100
NOTE
○Turn the steering stem nut 1/8 turn at a time maximum.
• Tighten the following:
Torque - Steering Stem Head Nut: 44 N·m (4.5 kgf·m, 33
ft·lb)
Front Fork Clamp Bolts (Lower): 29 N·m (3.0
kgf·m, 22 ft·lb)
STEERING 12-5
Steering
Steering Stem, Stem Bearing Removal
• Remove:
Front Wheel (see Wheels/Tires chapter)
Brake Hose Clamp (see Brake System chapter)
Caliper Mounting Bolts (see Brake System chapter)
Master Cylinder Clamp (see Brake System chapter)
Front Fender
Handlebar (see Handlebar Removal)
Front Fork (see Suspension chapter)
the steering stem head nut and washer.
• Remove
Remove
stem head.
• Pushing uptheonsteering
the
stem
base [A], and remove the steering
• stem nut [B], with the steering
stem nut wrench [C], then
remove the steering stem [D].
Special Tool - Steering Stem Nut Wrench: 57001-1100
off the upper stem bearing inner race (tapered roller
• Take
bearing) [A].
out the bearing outer races from the head pipe.
•○Drive
Remove the outer races pressed into the head pipe, using
the head pipe outer race remover [A], and hammer the
head pipe outer race remover to drive it out.
Special Tool - Head Pipe Outer Race Remover:
-1107
57001
NOTE
○If either steering stem bearing is damaged, it is recommended that both the upper and lower bearing (including outer races) should be replaced with new ones.
the lower stem bearing inner race (tapered roller
• Remove
bearing) [A] with its grease seal from the stem using suitable tools.
12-6 STEERING
Steering
Steering Stem, Stem Bearing Installation
the bearing outer race with new ones.
•○Replace
Apply grease to the outer races, and drive them into the
head pipe using the press shaft [A] and the drivers [B].
Special Tools - Head Pipe Outer Race Press Shaft: 57001
-1075
Head Pipe Outer Race Driver: 57001-1106
the lower inner races with new ones.
•○Replace
Apply grease to the lower inner race, and drive it onto
the stem using the steering stem bearing driver [A] and
adapter [B].
Special Tools - Steering Stem Bearing Driver: 57001-137
Steering Stem Bearing Driver Adapter:
57001-1092
grease to the upper inner race, and install it in the
• Apply
head pipe.
the stem through steering the head pipe and up• Install
per bearing, and hand-tighten the steering stem nut while
pushing up on the stem base.
Install the stem head and washer, and tighten the stem
head nut lightly.
Settle the bearing in place as follows;
○Tighten the steering stem nut to 39 N·m (4.0 kgf·m, 29
ft·lb) of torque. (To tighten the steering stem nut to the
specified torque, hook the wrench [A] on the steering stem
nut, and pull the wrench at the hole by 22.2 kg force [B]
in the direction shown.)
•
•
Special Tool - Steering Stem Nut Wrench: 57001-1100
○Check that there is no play and the steering stem turns
smoothly without rattles. If not, the steering stem bearings
may be damaged.
○Again back out the steering stem nut a fraction of a turn
until it turns lightly.
○Turn the steering stem nut lightly clockwise until it just
becomes hard to turn. Do not overtighten, or the steering
will be too tight.
Torque - Steering Stem Nut: 2.9 N·m (0.3 kgf·m, 26 in·lb)
• Install the front fork (see the Suspension chapter).
NOTE
○Tighten the fork upper clamp bolts first, next the stem
head nut, last the fork lower clamp bolt.
STEERING 12-7
Steering
Torque - Steering Stem Head Nut: 44 N·m (4.5 kgf·m, 33
ft·lb)
Front Fork Clamp Bolt:
Upper: 20 N·m (2.0 kgf·m, 15 ft·lb)
Lower: 29 N·m (3.0 kgf·m, 22 ft·lb)
• Install the parts removed (see the appropriate chapter).
WARNING
Do not impede the handlebar turning by routing the
cables, wires and hoses improperly (see the General Information chapter).
and Adjust:
• Check
Steering
Front Brake
Clutch Cable
Throttle Cable
12-8 STEERING
Steering Maintenance
Stem Bearing Lubrication
the steering stem (see Steering Stem Removal).
• Remove
a high flash-point solvent, wash the upper and
• Using
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 the outer races and the rollers.
Replace the bearing assemblies if they show wear or
damage.
Pack the upper and lower tapered roller bearings [A] in
the cages with grease, and apply a light coat of grease to
the upper and lower outer races.
Install the steering stem, and adjust the steering (see
Steering Stem, Stem Bearing Installation, Steering Adjustment).
Stem Bearing Wear, Damage Inspection
a high flash-point solvent, wash the upper and
• Using
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 the outer rase and the rollers.
Replace the bearing assembly if it show damage.
Stem Warp Inspection
the steering stem is removed, or if the steering
• Whenever
cannot be adjusted for smooth action, check the steering
stem for straightness.
If the steering stem shaft is bent [A], replace the steering
stem.
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
adhesive cement to the inside of the left handlebar
• Apply
grip [A].
the front master cylinder (see Front Master Cylinder
• Install
Installation in the Brakes chapter).
the handlebar clamps [B] so that the arrows [C] on
• Mount
the clamp point at the front [A].
the punch mark [D] on the handlebar to the mating
• Align
surface of each clamps of handlebar.
• Tighten the handlebar clamp bolts.
Torque - Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
○Tighten the clamp bolts, front first and then the rear.
If
the handlebar clamp is correctly installed, there will be no
gap at the front and a gap [E] at the rear after tightening.
Clutch Lever Installation
the clutch lever so that the mating surface [A] of the
• Install
clutch lever clamp is aligned with the punch mark [B].
Torque - Clutch Lever Clamp Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
ELECTRICAL SYSTEM 13-1
Electrical System
Table of Contents
Wiring Diagram.......................................................................................................................
Exploded View........................................................................................................................
Specifications .........................................................................................................................
Precautions.............................................................................................................................
Electrical Wiring......................................................................................................................
Wiring Inspection ..............................................................................................................
Ignition Timing ........................................................................................................................
Ignition Timing Adjustment................................................................................................
Flywheel Magneto ..................................................................................................................
Flywheel Magneto Removal..............................................................................................
Flywheel Magneto Installation...........................................................................................
Crankshaft Sensor Air Gap Inspection (KX65A6F ∼)........................................................
Flywheel Magneto Inspection ...........................................................................................
Ignition System .......................................................................................................................
Crankshaft Sensor Installation (KX65A6F ∼) ....................................................................
Crankshaft Sensor Air Gap Adjustment (KX65A6F ∼) ......................................................
Crankshaft Sensor Inspection (KX65A6F ∼) .....................................................................
Crankshaft Sensor Peak Voltage Inspection (KX65A6F ∼)...............................................
Ignition Coil Removal ........................................................................................................
Ignition Coil Installation .....................................................................................................
Ignition Coil Inspection......................................................................................................
Spark Plug Cleaning and Inspection.................................................................................
Spark Plug Gap Inspection ...............................................................................................
CDI Unit Removal .............................................................................................................
CDI Unit Inspection ...........................................................................................................
13-2
13-3
13-4
13-5
13-6
13-6
13-7
13-7
13-8
13-8
13-8
13-9
13-9
13-11
13-11
13-11
13-11
13-12
13-12
13-12
13-12
13-14
13-14
13-14
13-14
13
13-2 ELECTRICAL SYSTEM
Wiring Diagram
KX65A6F ∼
ELECTRICAL SYSTEM 13-3
Exploded View
1. Magneto Cover
2. Magneto Flywheel
3. Stator
4. CDI Unit
5. Ignition Coil
6. Spark Plug Cap
7. Spark Plug
8. Engine Stop Button
9. KX65-A1 ∼ A6
T1: 29 N·m (3.0 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 silicone sealant.
13-4 ELECTRICAL SYSTEM
Specifications
Item
Magneto
Stator coil resistance
Ignition System
Ignition Timing:
Ignition Coil:
3 Needle Arcing Distance
Primary Winding Resistance
Secondary Winding Resistance
Spark Plug:
Type
Gap
CDI. unit:
Standard
in the text
20.5° BTDC @6 000 r/min (rpm)
20.5° BTDC @7 100 r/min (rpm) (KX65A6F ∼)
7 mm or more
0.31 Ω ±15% (at 20°C)
3.1 kΩ ±15% (at 20°C)
NGK BR10EG
NGK B10EG (KX65-A1 ∼ A6 (US))
0.5 ∼ 0.6 mm
in the text
Special Tools - Flywheel Puller: 57001-252
Flywheel & Pulley Holder: 57001-1343
Hand Teste: 57001-1394
Peak Voltage Adapter: 57001-1415
Kawasaki Bond (silicone sealant): 56019-120
US: United States Model
ELECTRICAL SYSTEM 13-5
Precautions
There are numbers of important precautions that are
musts when servicing electrical systems. Learn and observe 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.
○Troubles may involve one or in some cases all items.
Never replace a defective part without determining what
CAUSED the failure. If the failure was caused by some
other item or items, they too must be repaired or replaced,
or the new replacement will soon fail again.
○Make sure all connectors in the circuit are clean and tight,
and examine wires for signs of burning, fraying, etc. Poor
wires and bad connections will affect electrical system operation.
○Measure coil and winding resistance when the part is cold
(at room temperature).
○Electrical Connectors
[A] Female Connectors
[B] Male Connectors
Safety Instructions
WARNING
The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil, or
high tension lead while the engine is running, or
you could receive a severe electrical shock.
13-6 ELECTRICAL SYSTEM
Electrical Wiring
Wiring Inspection
inspect the wiring for signs of burning, fraying,
• Visually
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.
Check the wiring for continuity.
○Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.
○Connect an ohmmeter between the ends of the leads.
○Set the meter to the × 1 Ω range, and lead the meter.
If the meter does not read 0 Ω the lead is defective. Replace the lead or the wiring harness if necessary.
•
•
ELECTRICAL SYSTEM 13-7
Ignition Timing
Ignition Timing Adjustment
the magneto cover.
• Remove
to see if the center mark of the three marks [A] on
• Check
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].
Tighten the stator plate mounting screws securely.
Torque - Stator Plate Mounting Screws:
kgf·m, 43 in·lb)
4.9 N·m (0.50
• Install the magneto cover.
Torque - Magneto Cover Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
The ignition timing can be adjusted for different power
band to suit to rider’s preference ability.
Remove the magneto cover.
Loosen the stator plate mounting screws.
Adjust the timing by shifting the stator position within the
three lines [A].
•
•
•
NOTE
○For best engine performance, it is very important to ad-
just the ignition timing within the adjustable range just
explained.
•
•
•
[A] Crankshaft Rotation
[B] Stator plate of movement
[C] Advance
[D] Retard
Tighten the stator plate mounting screws securely (see
Igniting Timing Adjustment).
Install the magneto cover.
Test ride the motorcycle and readjust the ignition timing if
necessary.
13-8 ELECTRICAL SYSTEM
Flywheel Magneto
Flywheel Magneto Removal
• Remove the magneto cover.
the flywheel steady, with the flywheel & pulley holder
• Hold
[A], and remove the flywheel nut [B].
Special Tool - Flywheel & Pulley Holder: 57001-1343
the flywheel puller [A] into the flywheel by turning
• Screw
it counterclockwise (left-hand thread).
the flywheel from the crankshaft by turning in the
• Remove
puller center bolt and tapping the head of the bolt lightly
with a hammer, while holding the puller body steady.
There is a woodruff key in the crankshaft tapered portion.
Special Tool - Flywheel Puller: 57001-252
CAUTION
Never strike the grab bar or the flywheel itself.
Strike the bar can bond it. If the flywheel is strike,
the magnets may lose their magnetism.
the mounting screws [A], and remove the stator
• Unscrew
plate [B] and the wiring grommet [C].
the band.
• Remove
Disconnect
the stator lead connectors from the harness.
•
Flywheel Magneto Installation
the stator plate.
• Install
silicone sealant around the stator wiring grommet
• Apply
[A], and set it in the notch [B] in the left crankcase half
securely, and route the leads according to the Cable,
Wire and Hose Routing section in the General Information chapter.
Torque - Stator Plate Mounting Screws:
kgf·m, 43 in·lb)
4.9 N·m (0.50
Sealant - Kawasaki Bond (silicone sealant): 56019-120
ELECTRICAL SYSTEM 13-9
Flywheel Magneto
a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the crankshaft taper [A] or in the hole [B]
in the flywheel. Dry them with a clean cloth.
the woodruff key [A] securely in the slot in the crank• Fit
shaft before installing the stator plate.
the flywheel steady, with the flywheel holder [A],
• Holding
and tighten the flywheel nut [B].
Special Tool - Flywheel & Pulley Holder: 57001-1343
Torque - Flywheel Nut: 29 N·m (3.0 kgf·m, 21 ft·lb)
Magneto Cover Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
Crankshaft Sensor Air Gap Inspection (KX65A6F ∼)
the magneto cover.
• Remove
Measure
crankshaft sensor air gap [A] (Clearance be• tween thetheflywheel
and the crankshaft sensor [B] core).
Crankshaft Sensor Air Gap
0.5 ±0.1 mm (0.020 ±0.004 in.)
If the gap is incorrect, reinstall the crankshaft sensor so
that the gap has correct clearance.
Flywheel Magneto Inspection
are three types of magneto problems: short, open
• There
(wire burned out), or loss in flywheel magnetism. A short
or open in one of the coil wires will result in either a low
output, or no output at all. A loss in flywheel magnetism,
which may be caused by dropping or hitting the flywheel
by leaving it near an electromagnetic field, or just by aging, will result in low output.
13-10 ELECTRICAL SYSTEM
Flywheel Magneto
check the stator coil resistance as follows.
•○To
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
Tester Range
× 1 Ω
Connections
Tester (+)
Black/Red
Lead
Tester (–) to
Black/White
Lead
Reading
214 Ω ±20%
KX65A6F ∼:
Tester Range
× 1 Ω
•
Connections
Tester (+)
Black/White
Lead
Tester (–) to
Black/Red
Lead
Reading
214 Ω ±20%
If there is more resistance than shown in the table, or no
hand tester reading (infinity) the stator has an open lead
and must be replaced. Much less than this resistance
means the stator is shorted, and must be replaced.
Using the highest resistance range of the hand tester,
measure the resistance between each leads and chassis ground.
Any hand tester reading less than infinity (∞) indicates a
short, necessitating stator replacement.
If the stator coils have normal resistance, but the voltage
check showed the magneto to be defective; then the rotor
magnets have probably weakened, and the rotor must be
replaced.
Special Tool - Hand Tester: 57001-1394
ELECTRICAL SYSTEM 13-11
Ignition System
Safety Instructions
WARNING
The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil, or
high tension lead while the engine is running, or
you could receive a severe electrical shock.
Crankshaft Sensor Installation (KX65A6F ∼)
the crankshaft sensor so that the air gap (clearance
• Install
between the flywheel and the crankshaft sensor core) has
correct clearance (see Flywheel Magneto Installation).
Crankshaft Sensor Air Gap Adjustment (KX65A6F ∼)
the magneto cover.
• Remove
Loosen
the
sensor screws [A].
• Insert a 0.5 crankshaft
mm
thickness
gauge [B] between the crank• shaft sensor core and the timing
plate.
While
pressing
the
crankshaft
sensor
toward the magneto
• flywheel, tighten the coil screws and remove
the thickness
•
gauge.
Check the air gap (See Flywheel Magneto Installation).
Crankshaft Sensor Air Gap: 0.4 ∼ 0.6 mm (0.016 ∼ 0.024
in.)
If the air gap is not within the specified range, readjust the
gap.
Crankshaft Sensor Inspection (KX65A6F ∼)
the following
• Remove
Magneto Lead Connector [A]
the hand tester [B] to the × 100 Ω range and connect
• Set
it to the magneto lead connector (crankshaft sensor lead)
connector.
Special Tool - Hand Tester: 57001-1394
If there is more resistance than the specified value, the
coil has an open lead and must be replaced. Much less
than this resistance means the coil is shorted, and must
be replaced.
Crankshaft Sensor Resistance
W/G ∼ W/R Leads: 396 ∼ 594 Ω (× 100 Ω)
the highest resistance range of the hand tester,
• Using
measure the resistance between the crankshaft sensor
leads and chassis ground.
Any hand tester reading less than infinity (∞) indicates a
short, necessitating replacement of the stator.
13-12 ELECTRICAL SYSTEM
Ignition System
Crankshaft Sensor Peak Voltage Inspection
(KX65A6F ∼)
the magneto lead connector [C].
• Disconnect
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
lead and red lead to White/Red lead of the magneto lead
adapter.
Kicking the primary kick, turn the engine 4 ∼ 5 seconds
with the transmission gear in neutral to measure the
crankshaft sensor peak voltage.
Repeat the measurement 5 or more times.
Crankshaft Sensor Peak Voltage
4.0 V or more
Standard:
Special Toos - Hand Tester: 57001-1394
Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
WARNING
Do not touch the metal portion of the Probe in case
of measuring the voltage, or you may receive a serious electric shock
If the voltage is less than the specified, replace the pickup
coil.
Ignition Coil Removal
• Remove:
Seat
•
•
•
Side Covers
Shroud
Fuel Tank
Disconnect the ignition coil primary lead [A].
Pull the plug cap off the spark plug.
Unscrew the mounting bolts [B], and remove the ignition
coil [C].
Ignition Coil Installation
• Installation is the reverse of removal.
Torque - Ignition Coil Mounting Bolts: 8.8 N·m (0.90 kgf·m,
78 in·lb)
Ignition Coil Inspection
Measuring arcing distance
The most accurate test for determining the condition of
the ignition coil is made by measuring arcing distance using
the coil tester for the 3-needle method.
Remove the ignition coil.
Connect the ignition coil (with the spark plug cap left installed on the spark plug lead) [A] to the tester [B], and
measure the arcing distance.
•
•
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
7 mm or more
Standard:
determine which part is defective, measure the arcing
• To
distance again with the spark plug cap removed from the
ignition coil lead.
If the arcing distance is subnormal as before, the trouble
is with the ignition coil itself. If the arcing distance is now
normal, the trouble is with the spark plug cap.
C: KX65A6F ∼
Measuring Coil Resistance
If the arcing tester is not available, the coil can be
checked for a broken or badly shorted winding with an
ohmmeter. However, an ohmmeter cannot detect layer
shorts and shorts resulting from insulation breakdown
under high voltage.
Remove the ignition coil.
Measure the primary winding resistance [A].
○Connect an ohmmeter between the coil terminals.
○Set the meter to the × 1 Ω range, and read the meter.
KX65A6F [C]
Measure the secondary winding resistance [B].
○Pull the spark plug cap off the lead.
Connect an ohmmeter between the spark plug lead and
the ground lead terminal.
Set the meter to the × 1 kΩ range, and read the meter.
If the meter does not read as specified, replace the coil.
If the meter reads as specified, the ignition coil windings
are probably good. However, if the ignition system still
does not perform as it should after all other components
have been checked, test replace the coil with one known
to be good.
•
•
•
•
•
Ignition Coil Winding Resistance
Primary Windings:
0.26 ∼ 0.36 Ω (× 1 Ω)
Secondary Windings:
KX65A6F ∼
Primary Windings:
Secondary Windings:
2.64 ∼ 3.57 Ω (× 1 kΩ)
0.36 ∼ 0.48 Ω (× 1 Ω)
5.4 ∼ 7.4 Ω (× 1 kΩ)
the spark plug lead for visible damage.
• Check
If the spark plug lead is damaged, replace the coil.
13-14 ELECTRICAL SYSTEM
Ignition System
Spark Plug Cleaning and Inspection
the spark plug, and visually inspect it.
• Remove
the spark plug, preferably in a sandblasting device,
• Clean
and then clean off any abrasive particles. The plug may
also be cleaned using a high flash-point solvent and a wire
brush or other suitable tool.
If the spark plug electrodes are corroded or damaged,
or if the insulator is cracked, replace the plug. Use the
standard spark plug.
Torque - Spark Plug: 26 N·m (2.6 kgf·m, 19 ft·lb)
Spark Plug Gap Inspection
the gap [A] with a wire-type thickness gauge.
• Measure
If the gap is incorrect, carefully bend the side electrode
[B] with a suitable tool to obtain the correct gap.
Spark Plug Gap
Standard:
0.5 ∼ 0.6 mm
CDI Unit Removal
the handlebar to the right. (KX65-A1 ∼ A6)
• Turn
Disconnect
harness connector [A].
• Unscrew thethemounting
bolt [B] and remove the CDI Unit
• [C].
KX65A6F ∼:
Disconnect the harness connector [A].
Remove the CDI Unit mounting bolts [B] and remove the
CDI Unit [C].
•
•
Torque - CDI Unit Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78
in·lb)
CDI Unit Inspection
CAUTION
When inspecting the CDI Unit observe the following
to avoid damage to the CDI Unit.
Do not disconnect the CDI Unit while the engine is
running.
This may damage the CDI Unit.
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.
•
•
•
○Measure
NOTE
the voltage with each lead connected correctly. The correct value may not be obtained if
disconnected.
○Maintain the correct value of compression pressure for
the cylinder. (Be sure to measure the voltage with the
spark plug installed to the cylinder head.)
the peak voltage adapter [A] between the termi• Connect
nal of primary lead (orange) and ground connection of the
lead of the ignition coil [B].
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Hand Tester: 57001-1394
Connection:
Tester Positive → Ground Lead [C]
Tester Negative →Orange Lead [D]
the gear to the neutral position, then push the engine
• Shift
stop button.
the engine by kicking the pedal several times to
• Crank
measure the peak voltage of the primary ignition coil.
Peak Voltage:
DC 115 V or above
WARNING
Do not touch the metal portion of the probe in case
of measuring the voltage, or you may receive a serious electric shock.
If the voltage is less than the specified value, see the next
page.
13-16 ELECTRICAL SYSTEM
Ignition System
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.
•
•
○Measure
NOTE
the voltage with each lead connected correctly. The correct value may not be obtained if
disconnected.
○Maintain the correct value of compression pressure for
the cylinder (Be sure to measure the voltage with the
spark plug installed to the cylinder head).
○Connect the peak voltage adapter [A] of the tester to the
terminals of the harness connector [B].
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B
Hand Tester: 57001-1394
Connection:
Adapter Positive → Black/Red Lead
Adapter Negative → Black/White Lead
○Crank the engine by kicking the pedal several times to
measure the peak voltage of the exciter (stator) coil.
Peak Voltage
DC 100 V or above
If the voltage is less than the specified, check the exciter
(stator) coil.
Engine Stop Function Check
Disconnect the engine stop button (switch) leads [A].
Start the engine.
Ground the stop button (switch) lead [B] of the main harness side while the engine is running.
If the engine does not stop, the CDI Unit is defective.
•
•
•
Engine Stop Button Electric Current Check (KX65A6F
∼)
Disconnect the engine stop button (switch) lead connector.
Start the engine.
Ground the stop button (switch) black/yellow lead of the
magneto lead while the engine is running.
If the engine does not stop, replace the CDI Unit.
•
•
•
APPENDIX 14-1
Appendix
Table of Contents
Troubleshooting Guide ...........................................................................................................
General Lubrication ................................................................................................................
Lubrication (Periodic Maintenance) ..................................................................................
Nut, Bolt, and Fastener Tightness ..........................................................................................
Tightness Inspection .........................................................................................................
Unit Conversion Table ............................................................................................................
14-2
14-6
14-6
14-7
14-7
14-8
14
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 over:
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Kick shaft return spring broken
Kick ratchet gear not engaging
No fuel flow:
No fuel in tank
Fuel tap turned off
Tank cap air vent obstructed
Fuel tap clogged
Fuel line clogged
Float valve clogged
Engine flooded:
Float level too high
Float valve worn or stuck open
Starting technique faulty
(when flooded, kick with the throttle fully
open to allow more air to reach the engine.)
No spark; spark weak:
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap not in good contact
Spark plug incorrect
CDI Unit trouble
Ignition coil trouble
Ignition coil resistor open
Flywheel magneto damaged
Wiring shorted or open
Fuel/air mixture incorrect:
Idle adjusting screw maladjusted
Slow jet or air passage clogged
Air cleaner clogged, poorly sealed, or missing
Starter jet clogged
Compression Low:
Spark plug loose
Cylinder head not sufficiently tightened
down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring and clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Cylinder base gasket damaged
Read valve damaged
Cylinder nut loose
Poor Running at Low Speed:
Spark weak:
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
CDI Unit trouble
Ignition coil trouble
Flywheel magneto damaged
Ignition coil lead or CDI Unit lead not in good
contact
Fuel/air mixture incorrect:
Idle adjusting screw maladjusted
Slow jet or air passage clogged
Air cleaner clogged, poorly sealed, or missing
Choke plunger stuck open
Float level too high or too low
Fuel tank air vent obstructed
Carburetor holder loose
Air cleaner duct loose
Compression Low:
Spark plug loose
Cylinder head not sufficiently tightened
down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/land clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Cylinder base gasket damaged
Reed valve damaged
Cylinder nut loose
Other:
CDI Unit trouble
Transmission oil viscosity too high
Brake dragging
Poor Running or No Power at High
Speed:
Firing incorrect:
Spark plug dirty, damaged, or maladjusted
Spark plug cap or high tension wiring damaged
Spark plug cap shorted or not in good contact
Spark plug incorrect
CDI Unit trouble
Ignition coil trouble
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 clogged
Air cleaner clogged, poorly sealed, or missing
Choke plunger stuck open
Fuel to carburetor insufficient
Water or foreign matter in fuel
Fuel tank air vent obstructed
Carburetor holder loose
Air cleaner duct loose
Fuel tap clogged
Fuel line clogged
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened
down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or
sticking)
Piston ring/and clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Cylinder base gasket damaged
Reed valve damaged
Cylinder nut loose
Engine rpm will not rise properly:
Choke plunger stuck open
Float level too high or too low
Main jet clogged
Throttle valve does not fully open
Air cleaner clogged
Muffler clogged
Water or foreign matter in fuel
Cylinder exhaust port clogged
Brake dragging
Clutch slipping
Overheating
Transmission oil level too high
Transmission oil viscosity too high
Crankshaft bearing worn or damaged
Knocking:
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
CDI Unit trouble
Overheating:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug incorrect
CDI Unit trouble
Fuel/air mixture incorrect:
Main jet clogged or wrong size
Fuel level in carburetor float bowl too low
Carburetor holder loose
Air cleaner poorly sealed, or missing
Air cleaner duct poorly sealed
Air cleaner clogged
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Brake dragging
Clutch slipping
Transmission oil level too high
Transmission oil viscosity too high
Lubrication inadequate:
Transmission oil level too low
Transmission oil poor quality or incorrect
Coolant incorrect:
Coolant level too low
Coolant deteriorated
Cooling system component incorrect:
Radiator clogged
Radiator cap trouble
Water pump not rotating
Clutch Operation Faulty:
Clutch slipping:
No clutch lever play
Clutch cable maladjusted
Clutch inner cable catching
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch release mechanism trouble
Clutch hub or housing unevenly worn
Clutch not disengaging properly:
Clutch lever play excessive
Clutch plate warped or too rough
Clutch spring tension uneven
Transmission oil deteriorated
Transmission viscosity too high
Transmission oil level too high
Clutch housing frozen on drive shaft
Clutch release mechanism trouble
Gear Shifting Faulty:
Doesn’t into gear; shift pedal doesn’t
return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear positioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Shift drum broken
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 broken
Shift fork guide pin worn
Drive shaft, output shaft, and/or gear
splines worn
Overshifts:
Gear positioning lever spring weak or broken
Shift mechanism arm spring broken
Abnormal Engine Noise:
Knocking:
CDI Unit trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken or stuck
Piston seizure or damaged
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Primary gear worn or chipped
Abnormal Drive Train Noise
Clutch noise:
Clutch housing/friction plate clearance excessive
Clutch housing gear/primary gear backlash
excessive
Metal chip jammed in clutch housing gear
teeth
Transmission noise:
Crankcase bearing worn or damaged
Transmission gear worn or chipped
Metal chip jammed in gear teeth
Transmission oil insufficient or too thin
Kick ratchet gear not properly disengaging
from kick gear
Output shaft idle gear worn or chipped
Drive chain noise:
Drive chain adjusted improperly
Chain worn
Rear and/or engine sprocket(s) worn
Chain lubrication insufficient
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Cylinder damaged
Other noise
Bracket, nut, bolt, etc.
not properly
mounted or tightened
Exhaust Smoke:
Excessive white smoke:
Throttle cable maladjusted
Brownish smoke:
Air cleaner clogged
Main jet too large of fallen out
Choke plunger stuck open
Float level too high
Handling and/or Stability
Unsatisfactory:
Handlebar hard to turn:
Control Cable routing incorrect
Wiring routing incorrect
Steering stem nut too tight
Bearing ball damaged
Bearing race dented or worn
Steering stem bearing lubrication inadequate
Steering stem bent
Tire air pressure too low
Handlebar shakes or excessively vibrates:
Tire worn
Swingarm sleeve or needle bearing damaged
Rim warped, or not balanced
Front, rear axle runout excessive
Wheel bearing worn
Handlebar clamp loose
Steering stem head nut loose
Handlebar pulls to one side:
Frame bent
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 viscosity too high
Front fork leg bent
Tire air pressure too high
Rear shock absorber maladjusted
(Too soft)
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Front fork, rear shock absorber spring weak
Rear shock absorber gas leaking
Rear shock absorber maladjusted
Brake Doesn’t Hold:
Disc brake:
Air in the brake line
Pad or disc worn
Brake fluid leak
Disc warped
Contaminated pads
Brake fluid deteriorated
Primary or secondary cup damaged
Master cylinder scratched inside
Brake maladjustment (lever or pedal play
excessive)
14-6 APPENDIX
General Lubrication
Lubrication (Periodic Maintenance)
lubricating each part, clean off any rusty spots with
• Before
rust remover and wipe off any grease, oil, dirt, or grime.
• Lubricate the points listed below with indicated lubricant.
○Whenever
NOTE
the vehicle has been operated under
wet or rainy conditions, or especially after using a
high-pressure water spray, perform the general lubrication.
Pivots: Lubricate with Motor Oil
Clutch Lever
Brake Lever
Kick Pedal
Shift Pedal
Drive Chain
Points: Lubricate with Grease [A].
Clutch Inner Cable Upper and Lower Ends
Throttle Inner Cable Upper Ends
Swingarm Pivot
Tie-Rod Pivot
Rocker arm Pivot
Steering Stem Bearing
Cables: Lubricate with Rust Inhibitor.
Throttle Cables
Clutch Cable [A]
the cable disconnected at the both ends, the cable
• With
[A] should move freely within the cable housing.
If cable movement is not free after lubricating, if the cable
is frayed, or if the cable housing is kinked, replace the
cable.
APPENDIX 14-7
Nut, Bolt, and Fastener Tightness
Tightness Inspection
the tightness of bolts and nuts listed here. Also,
• Check
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 them to the specified torque following the specified tightening sequence.
Refer to the appropriate chapter for torque specifications.
If torque specifications are not in the appropriate chapter,
see the Standard Torque Table. For each fastener, first
loosen it by 1/2 turn, then tighten it.
If cotter pins are damaged, replace them with new ones.
Nut, Bolt and Fastener to be checked
Wheels:
Spoke Nipples
Front Axle Nut
Rear Axle Nut
Final Drive:
Chain Adjuster Locknuts
Brakes:
Master Cylinder Clamp Bolts
Caliper Mounting Bolts
Brake Pedal Mounting Bolt
Suspension:
Front Fork Clamp Bolts
Rear Shock Absorber Mounting Bolt and Nut
Swingarm Pivot Shaft Nut
Tie-rod Mounting Nut
Steering:
Steering Stem Head Nut
Handlebar Clamp Bolts
Steering Stem Nut
Engine:
Engine Mounting Nuts
Engine Bracket Nuts
Cylinder Head Nuts
Shift Pedal Bolt
Muffler Mounting Bolt and Nut
Kick Pedal Bolt
Others:
Rear Frame Mounting Bolts
Front Fender Mounting Bolt
14-8 APPENDIX
Unit Conversion Table
Prefixes for Units:
Prefix
mega
kilo
centi
milli
micro
Symbol
M
k
c
m
µ
Units of Length:
×
×
×
×
×
Power
1 000 000
1 000
0.01
0.001
0.000001
Units of Mass:
kg
g
×
×
2.205
0.03527
=
=
lb
oz
=
=
=
=
=
=
=
=
=
gal (US)
gal (imp)
qt (US)
qt (imp)
pint (US)
pint (imp)
oz (US)
oz (imp)
cu in
Units of Volume:
L
L
L
L
L
L
mL
mL
mL
×
×
×
×
×
×
×
×
×
0.2642
0.2200
1.057
0.8799
2.113
1.816
0.03381
0.02816
0.06102
km
m
mm
×
×
×
0.6214
3.281
0.03937
=
=
=
mile
ft
in
=
=
=
=
=
=
kgf·m
ft·lb
in·lb
N·m
ft·lb
in·lb
=
=
=
=
=
=
kgf/cm²
psi
cmHg
kPa
psi
kPa
=
mph
=
=
=
=
PS
HP
kW
HP
Units of Torque:
N·m
N·m
N·m
kgf·m
kgf·m
kgf·m
×
×
×
×
×
×
0.1020
0.7376
8.851
9.807
7.233
86.80
Units of Pressure:
kPa
kPa
kPa
kgf/cm²
kgf/cm²
cmHg
×
×
×
×
×
×
0.01020
0.1450
0.7501
98.07
14.22
1.333
Units of Speed:
km/h
×
0.6214
Units of Force:
N
N
kg
kg
×
×
×
×
0.1020
0.2248
9.807
2.205
Units of Temperature:
=
=
=
=
kg
lb
N
lb
Units of Power:
kW
kW
PS
PS
×
×
×
×
1.360
1.341
0.7355
0.9863
MODEL APPLICATION
Year
Model
2000
KX65-A1
2001
KX65-A2
2002
KX65-A3
2003
KX65-A4
2004
KX65-A5
2005
KX65-A6
2006
KX65A6F
2007
KX65A7F
Beginning Frame No.
JKBKEAC□YA000001 or
JKAKX065AAA000001
JKBKXEAC□1A009001 or
JKBKX065AAA009001
JKBKXEAC□2A016001 or
JKBKX065AAA016001
JKBKXEAC□3A027001 or
JKBKX065AAA027001
JKBKXEAC□4A036001 or
JKBKX065AAA036001
JKBKXEAC□5A042001 or
JKBKX065AAA042001
JKBKXEAC□6A048001 or
JKBKX065AAA048001
JKBKXEAC□7A054001
JKBKX065AAA054001
□:This digit in the frame number changes from one machine to another.
Part No.99924-1252-08
Printed in Japan