KX65 (2010) - Motorcycle KAWASAKI - Free user manual and instructions

Product Type	Motocross Motorcycle
Brand	Kawasaki
Model	KX65 (2010)
Engine Type	2-stroke, single cylinder, liquid-cooled
Displacement	64 cc
Bore x Stroke	45.0 x 40.4 mm
Compression Ratio	8.4:1
Fuel System	Carburetor (Mikuni VM24SS)
Ignition	Digital CDI
Lubrication	Premix (fuel/oil ratio 32:1)
Transmission	6-speed, wet multi-disc clutch
Final Drive	Chain
Front Suspension	36 mm telescopic fork, adjustable
Rear Suspension	Uni-Trak linkage, adjustable preload
Front Brake	Single 220 mm disc
Rear Brake	Single 183 mm disc
Front Tire	60/100-14
Rear Tire	80/100-12
Wheelbase	1145 mm (45.1 in)
Seat Height	720 mm (28.3 in)
Ground Clearance	280 mm (11.0 in)
Dry Weight	57 kg (125.6 lbs)
Fuel Capacity	3.8 L (1.0 US gal)
Maintenance	Air filter cleaning, chain lubrication, premix preparation, regular oil changes (transmission), spark plug replacement
Safety Features	Throttle limiter, kill switch, sturdy frame, adjustable suspension for rider size

Frequently Asked Questions - KX65 (2010) KAWASAKI

What type of oil should I use for the premix?

Use a high-quality 2-stroke engine oil specifically designed for motorcycles. Recommended ratio is 32:1 (fuel to oil). Follow the manufacturer's instructions for the best performance.

How do I adjust the chain on the KX65?

Loosen the rear axle nut, then turn the chain adjuster bolts on both sides evenly to achieve a slack of about 30-40 mm. Tighten the axle nut to the specified torque. Always check chain alignment.

What spark plug does the KX65 use?

The recommended spark plug is NGK BR9ES or equivalent. Gap should be set to 0.6-0.7 mm.

How often should I change the transmission oil?

Change the transmission oil every 10-15 hours of riding or after every race event. Use 10W-40 motorcycle oil (about 500 mL).

Why won't my KX65 start?

Check the spark plug for fouling, ensure the kill switch is in the run position, verify fuel flow to the carburetor, and confirm the premix is correct. Also inspect the air filter for blockage.

What is the proper tire pressure for the KX65?

Front tire: 12-15 psi (0.8-1.0 bar). Rear tire: 12-15 psi (0.8-1.0 bar). Adjust based on terrain and rider preference.

How do I clean the air filter?

Remove the air filter, wash it in non-flammable solvent, let it dry, then apply air filter oil. Reinstall after ensuring it's completely dry. Clean every 5-10 hours of riding.

What is the recommended fuel octane?

Use premium unleaded gasoline with an octane rating of 91 or higher (RON). Avoid ethanol blends above 10%.

How do I adjust the throttle limiter?

Locate the throttle limiter screw on the carburetor. Turning it in reduces maximum throttle opening, ideal for beginners. Turn out for full power.

What are the common issues with the KX65?

Common issues include clutch slipping due to worn plates, carburetor clogging from stale fuel, and piston ring wear requiring top-end rebuilds every 30-40 hours.

USER MANUAL KX65 (2010) KAWASAKI

Black and white photo of a Kawasaki motorcycle with visible tracks, wheels, and engine components (no text or symbols on the bike body)

Motorcycle ServiceManual

QuickReferenceGuide

GeneralInformation1
FuelSystem2
CoolingSystem3
EngineTopEnd4
EngineRightSide	5
EngineRemoval/Installation	6
EngineBottomEnd/Transmission	7
Wheels/Tires	8
FinalDrive	9
Brakes	10
Suspension	11
Steering	12
ElectricalSystem	13
Appendix	14

This quick refe rence guidewill assist you in locating adesired topic or procedure.

- Bendthepag esbacktomatchthe blacktabofthedesiredchapternumberwiththeblacktabontheedgeateachtable ofcontentspage.

- Refertothesectionaltableofcontents fortheexactpagestolocatethespecificto picrequired.

Motorcycle ServiceManual

Allrightsreserved.Nopartsofthispublicationmaybereproduced,storedinaretrievalsystem,or transmittedinanyformorbyanymeans,electronicmechanicalphotocopying,recordingorotherwise, without the prior written permission of Quality Assurance Division/Consumer Products & Machinery Company/KawasakiHeavyIndustries,Ltd.,Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible carehasbeenaktentomakeitascompleteandaccurateaspossible.

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. Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmay notdepictactualmodelcomponentparts.

LISTOFABBREVIATIONS

Aampere(s)	lbpound(s)
ABDCafter	bottomdeadcentermmeter(s)
AC	alternatingcurrentmin		minute(s)
ATDcaftertop	deadcenter	N	newton(s)
BBDCbefore	bottomdeadcenter	Pa	pascal(s)
BDCbottom	deadcenterPShorsepower
BTDC	before top dead center	psi	pound(s) per square inch
°C	degree(s) Celsius	r	revolution
DC	direct current	rpm	revolution(s) per minute
F	farad(s)	TDC	top dead center
°F	degree(s) Fahrenheit	TIR	total indicator reading
ft	foot, feet	V	volt(s)
g	gram(s)	W	watt(s)
h	hour(s)	Ω	ohm(s)
L	liter(s)

This motorcycle is designed for a rider weighing less than 121 pounds (55 kg). Exceeding this limit could damage the motorcycle.

Foreword

Thismanualisdesignedprimarilyforuseby trainedmechanicsinaproperlyequippedshop. However, it contains enough detail and basic information to make useful to the owner who desire to perform his own basic maintenance and repair work. Abasicknowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repairs satisfactorily. Whenever the owner has insufficient experience or doubts as this is ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

Inordertoperformtheworkefficiently and toavoidcostlymistakes,readthetext,thoroughlyfamiliarizeyourselfwiththeprocedures beforestartingwork,andthendotheworkcarefullyinacleanarea.WhenIVERSpecialtoolsorequipmentarespecified,donotusemakeshift toolsorequipment.Precisionmeasurements canonlybemadeiftheproperinstrumentsare used,andtheuseofsubstitutetoolsmayadverselyaffectsafeoperation.

Togetthelongestlifeoutofyourmotorcycle:

• FollowthePeriodicMaintenanceChartintheServiceManual.
• Be alert for problems and non-scheduled maintenance.
• UsepropertoolsandgenuineKawasakimotorcycleparts. Specialtools, gauges, and testers that are necessary when servicing KawasakiMotorcyclesareintroduced by the ServiceManual. Genuinepartsprovided as sparepartsarelisted inthePartsCatalog.
• Follow the procedures in this manual carefully. Don't take shortcuts.
• Remembertokeepcompleterecordsof maintenanceandrepairwithdatesandanynew partsinstalled.

HowtoUsethisM anual

In this manual, the product is divided into its majors systems and the these systems makeup the manual's chap ters.

TheQuickReferenceGuideshowsyouall oftheproduct'ssystemandassistsinlocating theirchapter s. Each chapter in turn has its own comprehensiveTableofContents.

FoeExample, if you want ignition coil information, use the Quick Reference Guidetolocate the Electrical System chapter. Then, use

theTableofContentsonthefirstpageofthe chaptertofindtheignitioncoilsection.

Whenever you see these symbols, heed their instructions! Alwaysfollowsafeoperating and maintenancepractices.

DANGER

DANGERindicatesahazardoussituationwhich,ifnotavoided,willresultin deathorseriousinjury.

WARNING

WARNING indicates ahazardoussituation which, if not avoided, could result in deathorserious injury.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

NOTICEisusedtoaddresspracticesnot relatedtopersonalinjury.

This manual contains four more symbols which will help you distinguish different types of information.

NOTE

○Thisnotesymbolindicatespointsofparticularinterestformoreefficientandconvenientoperation.
- Indicatesaproceduralsteporworktobe done.
○Indicatesaproceduralsub-steporhowtodo theworkoftheproceduralstepitfollows. It also precedesthetextofaNOTE.
★Indicates a conditional step or what action to take based on the result of the test or inspection in the procedural step or sub-step follow.

Inmostchaptersanexplodedviewillustration ofthesystemcomponentsfollowstheTableof Contents.Intheseillustrationsyouwillfindthe instructionsindicatingwhichpartsrequiresspecifiedtighteningtorque,oil,greaseoralocking agentduringassembly.

GeneralInformation

TableofContents

Before Servicing 1-2

Model Identification.... 1-5

General Specifications.... 1-6

Periodic Maintenance Chart 1-9

Torque and Locking Agent.... 1-11

Special Tools and Sealants 1-14

Cable, Wire and Hose Routing.... 1-18

BeforeServicing

Beforestartingtopermaninspectionserviceorcarryoutadisassemblyandreassemblyoperationonamotorcycle,readtheprecautionsgivenbelow.Tofacilitateactualoperations,notes,illustrations,photographs,cautions,and detailed descriptions have been included in each chapter wherever necessary.Thissectionexplainstheitemsthatrequireparticularattentionduringtheremovalandreinstallationordisassemblyandreassemblyofgeneralparts.

Especiallynotethefollowing:

(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 an new part, clean off any dust or metal filings.

(2)BatteryGround

Disconnecttheground(−)cablefromthebatterybeforeperforminganydisassemblyoperations onthemotorcycle. This preventstheenginefromaccidentallyturningoverwhileworkisbeing carriedout, sparksfrombeinggeneratedwhiledisconnectingthecablesfromelectricalparts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive cabletothepositive(+)terminalofthebattery

(3) Installation, Assembly

Generally, installationorassemblyisthereverseofremovalordisassembly. However, if installationorassemblysequenceisgiveninthisServiceManual, followit. Notepartslocations and cable, wire, and hoseroutingduringremovalordisassemblysotheycanbeinstalledorassembledinthesameway. It is preferable to mark and record the locations and routing whenever possible.

(4) TighteningSequence

Wheninstallingbolts,nuts,orscrewsforwhichtighteningsequenceisgiveninthisService Manual,makesuretofollowthesequence.Wheninstallingapartwithseveralbolts,nuts,orscrews,startthemallintheirholesandtightenthemtoasnugfit,thusensuringthattheparthas beeninstalledinitsproperlocation.Then,tightenthemtothespecifiedtorqueinthetightening sequenceandmethodindicated.Iftighteningsequenceinstructionsarenotgiven,tightenthem evenlyinacrosspattern.Conversely,toremoveapart,firstloosenallthebolts,nuts,orscrews thatareretainingtheparta1/4-turnbeforeeremovingthem.

(5)Torque

WhentorquevaluesaregiveninthisServiceManual, usethem. Eithertoolittleortoomuch torquemayleadtoseriousdamage. Useagoodquality, reliabletorquewrench.

(6)Force

Commonsenseshoulddictatehowmuchforceisnecessaryinassemblyanddisassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenevertappingisnecessary,taplightlyusingawoodenorplastic-facedmallet.Use an impact driver for screws (particularly for the removing screws held by non-permanent locking agent)inordertoavoiddamagingthescrewheads.

(7)Edges

Watchforsharpedges, asthey could cause injury through care less handling, especially during major enginedisassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over.

(8)High-FlashPointSolvent

A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America standards solvent (generic name). Always follow manufacturer and container directions regarding the use of an unsolvent.

(9)Gasket,O-ring

ReplaceagasketoranO-ringwithanewpartwhendisassembling.Removeanyforeignmatter fromthematingsurfaceofthegasketorO-ringtoensureaperfectlysmoothsurfacetoprevent oilorcompressionleaks.

(10)LiquidGasket,LockingAgent

Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Applythemsparingly.Excessiveamountmayblockengineoilpassagesandcauseseriousdamage.

BeforeServicing

(11)Press

When using a press or divert to install a parts 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)BallBearingandNeedleBearing

Donotremoveaballbearingoraneedlebearingunlessitisabsolutelynecessary.Replaceany ballorneedlebearingsthatwereremovedwithnewones.Installbearingswiththemanufacturer and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the endoftheracethatcontactsthepressfitportion,andpressitevenlyoverthebasecomponent.

(13)OilSealandGreaseSeal

Replaceanyoilorgreasesealsthatwereremovedwithnewones,asremovalgenerallydamages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a forceuniformlytotheendofsealuntilthefaceofthesealisevenwiththeendofthehole,unless instructedotherwise.Whenpressinginanoilorgreasesealwhichhasmanufacturer'smarks, pressitinwiththemarksfacingout.

(14) Circlip, Retaining Ring, and Cotter Pin

Wheninstallingcirclipsandretainingrings, takecaretocompressorexpandthemonlyenoughtoinstallthemandnomore.Installtheirclipwithitschamferedsidefacingloadsideaswell.

Replaceanycirclips, retaining rings, and cotterpinsthat wereremoved with new ones, as removal weakens and deform sthem. Ifoldonesarereused, they could be comedetached while the motorcycle is driven, leading to a major problem.

(15)Lubrication

Enginewearisgenerallyatitsmaximumwhiletheengineiswarmingupandbeforeallthesliding surfaceshaveanadequatelubricativefilm.Duringassembly,makesuretoapplyoiltoanysliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative qualityandmaycontainforeignparticlesthatactasabrasives;therefore,makesuretowipeitoff and apply fresh grease or oil. Some oils and greases in particular should be used only in certain applicationsandmaybeharmfulifusedinanapplicationforwhichtheyarenotintended.

(16)DirectionofEngineRotation

To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positiverotationiscounterclockwiseasviewedfromtheleftsideoftheengine.Tocarryoutproper adjustment,itisfurthermorenecessarytorotatetheengineinthedirectionofpositiverotationas well.

(17)ReplacementParts

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 replacethesepartswithnewoneseverytimetheyareremoved. Although the previously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and cotterpinhavenotbeensodesignatedintheirrespectivetext, theyarereplacementparts.

(18)ElectricalLeads

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 "yellow/red" lead; it would be a "red/yellow" lead if the colors were reversed.

Unlessinstructedotherwise,electricalleadsmustbeconnectedtoleadsofthesamecolor.

Two-ColorElectrical

Lead (cross-section)	Color Indicated on the Lead	Color Indicated on the Wiring Diagram
	Yellow/Red	—Y/R—

BeforeServicing

(19)Inspection

Whenpartshavebeendisassembled,visuallyinspectthesepartsforthefollowingconditions orotherdamage.Ifthereisanydoubtastotheconditionofthem,replacethemwithnewones.

AbrasionCrackHardeningWarp

BentDent

Scratch

Wear

Colorchange

Deterioration

Seizure

(20)Specifications

Specificationtermsaredefinedasfollows:

"Standards"showdimensionsorperformanceswhichbrand-newpartsorsystemshave.

"ServiceLimits" indicate the usable limits. If the measurement show excessive wear or deteriorated performance, replaced damaged parts.

ModelIdentification

KX65-A1LeftSideView

Black and white photo of a Kawasaki motorcycle with visible dynamics and tires (no text or symbols)

KX65-A1RightSideView

Black and white exterior view of a Kawasaki motorcycle with visible tracks, tires, and gear (no text or symbols on the bike body)

GeneralSpecifications

ItemsKX65-A1~ A2		KX65-A3~ A6,A6F ~ ABF
Dimensions
OverallLength1580mm1590mm
OverallWidth690mm(KX65-A1),730mm(KX65-A2)760mm
OverallHeight925mm(KX65-A1),935mm(KX65-A2)955mm
Wheelbase1 1 1 0 m m 1120mm
Road Clearance	270 mm (KX65-A1), 280 mm (KX65-A2)	305 mm
Seat Height	720 mm (KX65-A1), 730 mm (KX65-A2)	760 mm
Dry Mass	53 kg	57 kg (KX65-A3 ~ A8F)
Curb Mass	-	60 kg (KX65A9F ~)
Front	26.5kg	28.5kg
Rear	29.5kg	31.5kg
FuelTankCapacity	3.8L	←
Engine
Type	2-stroke, single cylinder, piston reed valve	←
CoolingSystemLiquid-cooled	←
Bore and Stroke	44.5 × 41.6 mm	←
Displacement	64 cm3	←
Compression Ratio	8.4: 1	←
Carburetion System	MIKUNI VM24SS	←
Starting System	Primary kick	←
Ignition System	MAGNETO CDI	←
Ignition Timing	20.5° BTDC @6 000 r/min (rpm)	←
		20.5°BTDC @7100r/min (rpm) (KX65A6F ~)
Spark Plug	NGK BR10EG (US) NGK B10EG	←
		NGKBR10EG (KX65A6F ~)
PortTiming
Intake:
Open	Full open	←
Close	—	←
Scavenging:
Open	61.8° BBDC	←
Close	61.8° ABDC	←
DURATION	123.6°	←
Exhaust:
Open	91.5° BBDC	←
Close	91.5° ABDC	←
DURATION	183°	←
LubricationSystem (Gasoline:Oil)	Petrolmix(32:1)	←

GeneralSpecifications

ItemsKX65-A1~ A2		KX65-A3~ A6,A6F ~ ABF
DriveTrainPrimaryReductionSystem:TypeGear←ReductionRatio3.500(77/22)←ClutchTypeWet,multidisc←Transmission:TypeGearRatios:1st2nd3rd4th5th6thFinalDriveSystem:TypeReductionRatioOverall Drive RatioTransmissionOil:GradeViscosityCapacity	6-speed, constant mesh, return shiftChaindrive3.538(46/13)13.416 @Top gearAPI SG, SH, SJ, SL or SM with JASO MA, MA1orMA2SAE 10W-400.5 L	←←3.615 (47/13)13.703 @Top gear←←←
FrameTypeSteeringAngleCaster (Rake Angle)TrailFront Tire:SizeTypeRearTire:SizeTypeRimSize:FrontRearFrontSuspension:TypeWheel TravelRearSuspension:TypeWheel Travel	Tubular, semi-double cradle40°toeitherside26.5°60 mm60/100-14 30Mtube type80/100-12 41Mtube type14×1.4012 × 1.60Telescopic fork210 mmSwingarm (Uni-trak)225 mm	←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←←→

1-8GENERALINFORMATION

GeneralSpecifications

ItemsKX65-A1~ A2	KX65-A3~ A6,A6F ~ ABF
BrakeType:FrontandRearSingledisc←EffectiveDiscDiameter:Front154.8mm←Rear146mm←

Specificationsaresubjecttochangewithoutnotice, and may not apply to every country.
US:UnitedStatesModel

PeriodicMaintenanceChart

The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.

FREQUENCY OPERATION	After each race(or 2.5hr.)	Every 3races (or7.5 hr.)	Every 5races (or12.5 hr.)	Every 10races (or25 hr.)	As required
Clutch-adjust	●
Clutchandfrictionplates-inspect†		●	R
Throttlecable-adjust	●
Sparkplug-clean,gap†	●	R
Aircleanerelement-clean	●
Aircleanerelement-replaceWhendamaged
Carburetor-inspect/adjust	●
Transmissionoil-change		●
Pistonandpistonring-clean/inspect†		●	R
Cylinderhead,cylinder-inspect		●
Mufflerbody-clean/inspect†	●
Mufflerbodypacking-change		●
Smallendbearing-inspect†		●		R
Kickpedalandshiftpedal-clean	●
ExhaustpipeO-ring-replace		●
Enginesprocket-inspect†	●
Coolant-inspect†	●				R
Waterhoses,connections-inspect†	●
Reedvalve-inspect†	●
Brakeadjustment-inspect†	●
Brakepadwear-inspect†			●
Brakefluidlevel-inspect†		●
Brakefluid-change	Every2years
Brakemastercylindercupanddustseal-replaceEvery2years
Brakecaliperfluidsealanddustseal-replaceEvery2years
Brakehose-replaceEvery4years
Brakehoses,connections-inspect†	●
Spoketightnessandrimrunout-inspect†	●
Drivechain-adjust	●
Drivechain-lubricate	●
Drivechainwear-inspect†			●
Drivechainslipperandguide-replaceWhendamaged
Frontfork-inspect/clean	●
Frontforkoil-change	1sttimeafter2races,thenevery5races
Nuts,bolts,fasteners-inspect†	●
Fuelsystem-clean	●
Fuelhose-replace	Every4years

1-10GENERALINFORMATION

PeriodicMaintenanceChart

OPERATION\FREQUENCY	After each race(or 2.5hr.)	Every 3races (or7.5 hr.)	Every 5races (or12.5 hr.)	Every 10races (or25 hr.)	As required
Fuelhoses,connections-inspect†	●
Steeringplay-inspect†	●
Steeringstembearing-grease			●
Rearsprocket-inspect†			●
Generallubrication-perform	●
Wheelbearing-inspect†				●
SwingarmandUni-Traklinkagepivots-grease			●
SwingarmandUni-Traklinkagepivots-inspect†			●
Rearshockoil-replace1sttimeafter2races,thenevery5races

†:Replace,add,adjust,cleanortorqueifnecessary.
R:Replace

TorqueandLockingAgent

Tightenallboltsandnutstothepropertorqueusinganaccuratetorquewrench.Ifinsufficiently tightened,aboltornutmaybecomedamaged,stripaninternalthread,orbreakandthenfallout.The followingtableliststhetighteningtorqueforthemajorboltsandnuts,andthepartsrequiringuseofa non-permanentlockingagentorliquidgasket.

When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half a turn andthentightentospecifiedtorque.

Lettersusedinthe"Remarks"columnmean:

L: Applyanon-permanentlockingagenttothethreads.

Lh:Left-handThreads.

S: Tightenthefastenersfollowingthespecifiedsequence.

Fastener	Torque			Remarks
	N·m	kgf·mft·lb
FuelSystem
RearFrameMountingBolts343.525
CarburetorClampScrews1.50.15 13in·lb
Carburetor Holder Mounting Bolts	8.8	0.90	78 in·lb
AirCleanerHousingPlateNuts	3.00.31	27in·lb
AirCleanerHousingMountingBolts	8.80.90	78in·lb
ReedValveScrews	9.8	1.0	87in·lb
CoolingSystem
Radiator Mounting Bolts	8.8	0.90	78 in·lb
Shroud Mounting Bolts	8.8	0.90	78 in·lb
Air Bleeder Bolt	8.8	0.90	78 in·lb
Water Pump Cover Bolts	8.8	0.90	78 in·lb
Water Pump Impeller Bolt	8.3	0.85	73 in·lb
Water Hose Clamp Screws	1.5	0.15	13 in·lb
Coolant Drain Plug (Water Pump)	8.8	0.90	78 in·lb
Water Pump Cover Fitting Bolts	5.9	0.60	52 in·lb
EngineTopEnd
CylinderHeadNuts	252.518
SparkPlug	262.619
CylinderNuts	252.518
Muffler Mounting Bolts	8.8	0.90	78 in·lb	L
ExpansionChamberDamperMountingBolt, Nut	8.80.90	78in·lb
Inner Pipe Mounting Bolts	5.9	0.6	52 in·lb	L
EngineRightSide
Primary Gear Nut (KX65A6F ~)	49	5.0	36	Lh
Clutch Spring Bolts	9.3	0.95	82 in·lb
ClutchHubBolt	646.547
Ratchet Guide Bolt	8.8	0.90	78 in·lb
Ratchet Guide Screw	5.2	0.53	46 in·lb
Kick Pedal Bolt	12	1.2	104 in·lb
Right Engine Cover Bolts	8.8	0.90	78 in·lb
Oil Filler Cap	1.5	0.15	13 in·lb
Gear Set Lever Screw	8.8	0.90	78 in·lb

TorqueandLockingAgent

Fastener	Torque			Remarks
	N·mkgf·mft·lb
EngineRemoval/Installation
EngineMountingNuts252.518
Engine Mounting Nuts (KX65-A3 ~)	29	3.0	21
SwingArmPivotShaftNut697.051
EngineBottomEnd/Transmission
CylinderStud	—			L(Planted Side)
CrankcaseBolts	8.80.9078in·lb
ShiftPedalBolt	8.80.9078in·lb
EngineOilDrainPlug	202.015
BearingRetainingScrews	8.80.9078in·lb
ShiftDrumOperatingPlateBolt	242.417	L
Shift Drum Plate Mounting Screws	5.2	0.53	46 in·lb	L
GearSetLeverScrew	8.80.9078in·lb
FlywheelNut	293.021
Wheels/Tires
FrontAxleNut	798.058
RearAxleNut	798.058
SpokeNipple	Not less than1.5	Not less than0.15	Not less than 13 in·lb
FinalDrive
RearAxleNut	798.058
RearSprocketBolts	262.720
Brakes
CaliperMountingBolts(Front,Rear)	252.518
BrakeHoseBanjoBolts	252.518
Master Cylinder Clamp Bolts	8.8	0.90	78 in·lb	S
Rear Master Cylinder Mounting Screws	9.8	1.0	87 in·lb
RearMasterCylinderPushRodLocknut181.813
Brake Disc Mounting Bolts (Front, Rear)	9.8	1.0	87 in·lb	L
Caliper Bleed Valves (Front, Rear)	7.8	0.80	69 in·lb
BrakePedalMountingBolt	252.518
Brake Lever Adjuster locknut	4.9	0.50	43 in·lb
BrakePadBolts	181.813
Suspension
FrontForkClampBolts(Upper)	202.014
FrontForkClampBolt(Lower)	293.022
ForkBottomAllenBolt	202.014	L
FrontForkTopPlug	222.216
SwingarmPivotShaftNut	697.051
RearShockAbsorberMountingBolt(Upper)	394.029
RearShockAbsorberMountingNut(Lower)	343.525
Tie-rodMountingNuts(Front,Rear)	596.043

TorqueandLockingAgent

Fastener	Torque			Remarks
	N·mkgf·mft·lb
RockerArmPivotNut838.561CaliperMountingBoltsRearFrameMountingBolts343.525	252.518
SteeringSteeringStemHeadNut444.533SteeringStemNut2.90.3026in·lbHandlebarClampBoltsClutchLeverClampBoltsFrontForkClampBolts(Upper)FrontForkClampBolts(Lower)293.022	252.5188.80.9078in·lb202.015
ElectricalSystemMagnetoCoverBolts8.80.9078in·lbFlywheelNutStatorPlateMountingScrewsIgnitionCoilMountingBoltsCDI Unit Mounting BoltsSparkPlug	293.0214.90.5043in·lb8.80.9078in·lb8.8262.619	0.90	78 in·lb

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.

BasicTorqueforGeneralFasteners

Threadsdia. (mm)	Torque
	N·m	kgf·m	ft·lb
5	3.4 ~ 4.9	0.35 ~ 0.50	30 ~ 43 in·lb
6	5.9 ~ 7.8	0.60 ~ 0.80	52 ~ 69 in·lb
8	14 ~ 19	1.4 ~ 1.9	10.0 ~ 13.5
10	25 ~ 34	2.6 ~ 3.5	19.0 ~ 25
12	44 ~ 61	4.5 ~ 6.2	33 ~ 45
14	73 ~ 98	7.4 ~ 10.0	54 ~ 72
16	115 ~ 155	11.5 ~ 16.0	83 ~ 115
18	165 ~ 225	17 ~ 23	125 ~ 165
20	225 ~ 325	23 ~ 33	165 ~ 240

1-14GENERALINFORMATION

SpecialToolsandSealants

BearingPullerAdapter: 57001-136

Simple line drawing of a mechanical component with a flanged top and central hole (no text or symbols)

SteeringStemBearingDriver: 57001-137

Line drawing of a cylindrical mechanical component with a textured top and flange (no text or symbols)

InsideCirclipPliers: 57001-143

Line drawing of a pair of pliers (no text or symbols)

OutsideCirclipPliers: 57001-144

Line drawing of a pair of needle tips (no text or symbols)

BearingPuller: 57001-158

Technical line drawing of a mechanical clamp or clamping device (no text or symbols)

ForkCylinderHolderHandle: 57001-183

Simple line drawing of a T-shaped tool or rod with a base, no text or symbols present.

FlywheelPuller, M12×1.75: 57001-252

Technical line drawing of a mechanical clamp or fitting with threaded end and flange (no text or symbols)

PistonPinPullerAssembly: 57001-910

Technical line drawing of a cylindrical mechanical component with multiple bolted and threaded parts (no text or symbols)

ForkCylinderHolderAdapter: 57001-1011

Technical line drawing of a conical mechanical component (no text or symbols)

OilSeal&BearingRemover: 57001-1058

Technical line drawing of a mechanical component assembly (no text or symbols)

SpecialToolsandSealants

RimProtector:

57001-1063

Five identical curved metal tools or clips arranged in a row, no text or symbols visible.

BeadBreakerAssembly:

57001-1072

Line drawing of a manual tool with clamps and handle (no text or symbols)

HeadPipeOuterRacePressShaft:

57001-1075

Technical line drawing of a mechanical component with threaded ends and a cylindrical shaft (no text or symbols)

SteeringStemBearingDriverAdapter,29. :

57001-1092

Simple line drawing of a cylindrical mechanical component (no text or symbols)

SteeringStemNutWrench:

57001-1100

Line drawing of a mechanical wrench tool (no text or symbols on the diagram itself)

HookWrenchR37.5,R42:

57001-1101

Technical line drawing of two mechanical wrenches (no text or symbols)

HeadPipeOuterRaceDriver,46.5:

57001-1106

Technical line drawing of a mechanical component with a flanged top and central hole (no text or symbols)

HeadPipeOuterRaceRemoverID>37mm:

57001-1107

Technical line drawing of a mechanical clamp or bracket component (no text or symbols)

BearingDriverSet:

57001-1129

Isometric line drawing of a box containing multiple circular components, no text or symbols present

ForkOuterTubeWeight:

57001-1218

Technical line drawing of a mechanical component with no visible text or symbols

1-16GENERALINFORMATION

SpecialToolsandSealants

FrontForkOilSealDriver: 57001-1219

Technical line drawing of a cylindrical mechanical component with internal cavities (no text or symbols)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

ForkOilLevelGauge: 57001-1290

Technical line drawing of a mechanical assembly with cylindrical components and threaded rods (no text or symbols)

CrankcaseSplittingToolAssembly: 57001-1362

Technical line drawing of a mechanical clamp or bracket assembly with four bolts and three pins (no text or symbols)

HandTester: 57001-1394

Technical line drawing of a mechanical housing or enclosure with internal components and mounting holes (no text or symbols)

PeakVoltageAdapter: 57001-1415

Pure electrical circuit lines without any symbols

CrankShaftJig: 57001-1439

Technical line drawing of two mechanical components with mounting holes (no text or symbols)

GraduatedCylinder&Tube: 57001-1584

Technical line drawing of a U-shaped pipe fitting with two cylindrical components and a black-and-white striped section (no text or symbols)

Flywheel&PulleyHolder: 57001-1605

Technical line drawing of a mechanical clamp or bracket assembly with mounting holes and mounting points (no text or symbols)

FuelLevelGaugeAdapter,M16×1:57001-1661

Technical line drawing of a mechanical component with threaded and threaded sections (no text or symbols)

SpecialToolsandSealants

LiquidGasket,TB1211:

56019-120

Line drawing of a cylindrical tool with a pointed tip and a flanged end, shown without any text or symbols.

LiquidGasket, TB1105B:

92104-002

Line drawing of a cylindrical tool with a flanged tip and a side tab, shown without any text or symbols.

1. ThrottleCable
2. Carburetor
   3.BreatherHose
   4.AirVentHose
3. OverflowHose
4. The hoses are passed from the left side of the engine through the clampin order of the air vent those, the overflow whose and the breather hose as shown in figure.
   7.CDIUnit(KX65-A1\~A6)

8.Clamp

9.RubberDamper(Noteitsinstallingdirection.)

1. ClutchCable
2. EngineStopButtonLead
   12.Band
3. Install the kickped also that it should be parallel to the frame as shown in figure.
   14.KX65-A1\~A2
   15.KX65-A3\~A6

Cable, Wire and Hose Routing

1.BreatherHose
2. Runthethrottlecableunderthebreatherhose.
3.Radiator
4.CDIUnit(KX65-A1\~A6)
5. Clamp(KX65-A1\~A6)
6.ThrottleCable
7. Clampashowninfigure.(Besuretheclampscrewpositionisinside.)
8. Clampashowninfigure.
9.CylinderHead
10.Cylinder
11.WaterPumpCover
12. EngineStopButtonLead(KX65A6F\~)

GB090503W4 C

1. Clamp
   2.CDIUnit(KX65-A1\~A6)
   3.Band
2. Clampthemagnetoleadsattheupperpartoftheleftonthecarburetorholder.
   5.MagnetoLeads
   6.ShiftPedal
   7.19±10mm(ShiftPedalPosition)
3. EngineStopButtonLead
4. IgnitionCoil
5. EngineStopButtonLeadGround
   11.CDIUnitGroundLead

Cable, Wire and Hose Routing

GB090177W4 C

1. FrontBrakeReservoir
   2.BanjoBolts
2. Clamp
   4.FrontBrakeDisk
   5.BleedValves
   6.FrontBrakeCaliper
3. RearBrakeCaliper
   8.RearBrakeDisk
4. RearBrakeReservoir
   10.RearBrakeMasterCylinder
   11.Bendthecotterpinendbyalongthejointpin.
5. Whitepaintmark

KX65A6F\~

1. ThrottleCable
2. ClutchCable
   3.Band
3. EngineStopButtonLead

4. Clamp
   6.CDlunit
   7.Band
   8.CDIunitGro undLead

5. Ignition Coil Primary Lead
   10.IgnitionCoilGrou ndLead
   11.IgnitionCoil
   12.Band
   13.ClamptheMagnet oLead
   14.KX65A6F\~A8F
   15.KX65A9F\~

FuelSystem

TableofContents

Exploded View.... 2-2

Specifications 2-4

Throttle Grip and Cable 2-5

Free Play Inspection 2-5

Free Play Adjustment.... 2-5

Throttle Cable Installation 2-6

Cable Lubrication 2-6

Cable Inspection 2-6

Carburetor 2-7

Idle Speed Inspection 2-7

Idle Speed Adjustment.... 2-7

Service Fuel Level Inspection 2-7

Service Fuel Level Adjustment 2-8

Carburetor Removal 2-9

Carburetor Installation.... 2-10

Fuel Inspection.... 2-11

Carburetor Disassembly 2-11

Carburetor Assembly 2-12

Carburetor Cleaning 2-13

Carburetor Inspection 2-13

Air Cleaner 2-15

Air Cleaner Housing Removal 2-15

Air Cleaner Housing Installation.... 2-15

Element Removal.... 2-15

Element Installation.... 2-15

Element Cleaning and Inspection 2-16

Fuel Tank 2-17

Fuel Tank Removal 2-17

Fuel Tank Installation 2-17

Fuel Tap Removal 2-17

Fuel Tap Installation 2-17

Fuel Tap Inspection.... 2-18

Fuel Tank and Tap Cleaning 2-18

Reed Valve 2-19

Reed Valve Removal 2-19

Reed Valve Installation 2-19

Reed Valve Inspection 2-19

Fuel Hose 2-20

FuelHosesandConnectionsCheck....2-20

GC020501W4 C

1. ThrottleCable
   2.ThrottleGrip
2. CarburetorHolder
   4.CarburetorCap
   5.Spring
   6.Retainer
   7.JetNeedleClip
   8.JetNeedle
   9.ThrottleValve
   10.ChokeKnob
   11.IdleAdjustingScrew
   12.Spring

13.AirScrew
14.SlowJet
15.FloatValveNeedle
16.MainJet
17.Float
18.ReedValve
T1:8.8N·m(0.90kgf·m,78in·lb)
T2:1.5N·m(0.15kgf·m,13in·lb)
T3:9.8N·m(1.0kgf·m,87in·lb)
G:Applygrease.
O:Applyoil.

ExplodedView

1.FuelTankCap
2.FuelTank
3.FuelTap
4.AirCleanerHousing
5. Element
6.Frame
7.Holder
8.AirCleanerDuct
9.KX65A6F\~

T1:34N·m(3.5kgf·m,25ft·lb)

T2:8.8N·m(0.90kgf·m,78in·lb)

T3:3.0N·m(0.31kgf·m,27in·lb)

G:Applygrease.

O:High-qualityfoam-airfilteroil

GC02375BW4 C

Specifications

Item	Standard		Service Limit
	KX65-A1 ~ A2	KX65-A3 ~
Throttle Grip Free Play and Cable	2 ~ 3 mm	←	- - -
Carburetor
Make/TypeMIKUNIVM24SS		← - - -
MainJet	#230#190		- - -
ThrottleValveCutaway#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)	←	- - -
ServiceFuelLevel(belowthe BottomEdgeofthe Carburetor Body)	0.5±1mm	← - - -
Float Height	21.1 ±1 mm	←	- - -
AirCleaner
ElementOil	High-qualityfoam-airfilteroil		- - -
ReedValve
Reed Warp	- - -		0.5 mm

Special Tools - Fuel Level Gauge Adapter M16 × 1: 57001-1661
GraduatedCylinder&Tube:57001-1584

ThrottleGripandCable

Ifthethrottlegriphasexcessivefreeplayduetocable stretchormis-adjustment,therewillbeadelayinthrottle response.Also,thethrottlevalvemaynotopenfullyatfull throttle.Ontheotherhand,ifthethrottlegriphasnoplay, thethrottlewillbehardtocontrol,andtheidlespeedwill beerratic.CheckthethrottlegripplayperiodicallyinaccordancewiththePeriodicMaintenanceChart,andadjustthe playifnecessary.

ThethrottlecableroutingisshowninCable, Wire and HoseRoutingintheGeneralInformationchapter.

FreePlayInspection

• Checkthethrottlegripfreeplay[B]bylightlyturningthe throttlegripAbackandforth.
  ★Ifthefreeplayisimproper,adjustthethrottlecable.

ThrottleGripFreePlay

Standard: 2\~3mm

FreePlayAdjustment

• LoosenthelocknutAattheupperendofthethrottle cable.
• Turntheadjuster[B]untiltheproperamountofthrottle gripfreeplayisobtained.
• Tightenthelocknut.

★ Ifthethrottlegripfreeplaycannotbeadjustedwiththe adjusterattheupperendofthethrottlecable,usethe cableadjusterAatthecarburetor.
- Pullthebootoffofthecarburetortop.Makethenecessary freeplayadjustmentatthelowercableadjuster,tighten thelocknut[B],andinstalltheboot.
- Turnthehandlebarfromsidetosidewhileidlingtheengine.Ifidlespeedvaries,thethrottlecablemaybepoorly routedoritmaybedamaged.

WARNING

Operation with improperly adjusted, incorrectly routedordamagedcablescouldresultinanunsafe ridingcondition. Followtheservicemanualtobe makesuretocorrectanyoftheseconditions.

ThrottleGripandCable

Throttle Cable Installation

• InstallthethrottlecableinaccordancewiththeCable, WireandHoseRoutingsectionintheGeneralInformationchapter.
• Aftertheinstallation,adjusteachcableproperly.

WARNING

Operationwithincorrectlyroutedorimproperlyadjustedcablescouldresultinanunsaferidingcondition.Besurethecablesareroutedcorrectlyand properlyadjusted.

CableLubrication

Wheneverthecableisremoved,andinaccordancewith thePeriodicMaintenanceChart(seeGeneralInformation chapter),dothefollowing.

• ApplyathincoatingofgreaseAothecableupperend.
• LubricatethecableAwithapenetrating rustinhibitor.

CableInspection

• Withthet hrottlecableAdisconnectedatbothends,the cableshouldmovefreelywithinthecablehousing.
  ★ Ifcablemovementisnotfreeafterlubricating,ifthecable isfra yed,orifthehousingiskinked,replacethecable.

Carburetor

Sincethecarburetorregulatesandmixesthefuelandair goingtotheengine,therearetwogeneraltypesofcarbure-tortrouble:toorichamixture(toomuchfuel),andtoolean amixture(toollittlefuel).Suchtroublecanbecausedby dirt,wear,maladjustment,orimproperfuellevelinthefloat chamber.Adirtyordamagedaircleanercanalsoalterthe fueltoairratio.

IdleSpeedInspection

• Starttheengineandwarmitupthoroughly.
• Withtheengineidling,turnthehandlebartobothsides.
  ★Ifhandlebarmovementchangestheidlespeed,thethrottlecablemaybeimproperlyadjustedorincorrectlyrouted,oritmaybedamaged.Besuretocorrectanyofthese conditionsbeforeriding(seeCable,WireandHoseRoutingintheGeneralInformationchapter).

WARNING

Operationwithimproperlyadjusted,incorrectly routedordamagedcablescouldresultinanunsafe ridingcondition.Followtheservicemanualtobe makesuretocorrectanyoftheseconditions.

• Checkidlespeed.
  ★Adjustitasneeded.

IdleSpeedAdjustment

• FirstturnintheairscrewAuntilitseatslightly,andback itout2turns(KX65-A1\~A2).
• FirstturnintheairscrewAuntilitseatslightly,andback out11/2turns(KX65-A3\~).
• Starttheengineandwarmitupthoroughly.
• Turntheidleadjustingscrew[B]toobtaindesiredidle speed. Ifnoidleispreferred,turnoutthescrew until the enginestops.
• Openandclosethethrottleafewtimestomakesurethat theidlespeedisasdesired. Readjustifnecessary.

ServiceFuelLevelInspection

WARNING

Gasoline is extremely flammable and can be explosiveundercertainconditions. Alwaysstopthe engineanddonotsmoke. Makesuretheareais wellventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

• TurnthefueltaptotheOFFposition.
• Removethefueltank(seeFuelTankRemoval).

Carburetor

• Removethecarburetor, and hold it in true vertical position on a stand. The fuel hose and carburetor cabledonot havetober removed to inspect the fuel level A.
• Putthefueltankonabench, and connect the fueltapto the carburetor using asuitable hose.
• Removethedrainplugfromthebottomofthefloatbowl, andscrewafuellevelgaugeadapter[B]intothedrain plughole.
• Connectofthegraduatedcylinder&tube[C]tofuellevel gaugeadapter.

SpecialTools-FuelLevelGaugeAdapterM16×1:57001 -1661

GraduatedCylinder&Tube:57001-1584

• Holdthegaugeverticallyagainstthesideofthecarburetorbodysothatthe"zero"line[D]isseveralmillimeters higherthanthebottomedge[E]ofthecarburetorbody.
• TurnthefueltaptotheONpositiontofeedfueltothe carburetor.
• Waituntilthefuellevelinthegaugesettles.
• Keepingthegaugevertical, slowly lower the gauge until the "zero" line is even with the bottom edge of the carburetorbody.

NOTE

○Donotlowerthe"zero"linebelowthebottomedgeof thecarburetorbody. Ifthegaugeisloweredandthen raisedagain, thefuellevelmeasureshowssomewhat higherthantheactualfuellevel. Ifthegaugeislowered toofar, dumpthefueloutofitintoasuitableconta iner andstarttheprocedureoveragain.

- Readthefuellevelinthegaugeandcompareittothe specification.

ServiceFuelLevel(belowthebottomedgeofthecarb. body)

Standard: 0.5 ± 1 mm

★ Ifthefuellevelisincorrect,adjustit.
- TurnthefueltaptotheOFFpositionandremovethefuel levelgauge.
- Installthedrainplugonthebottomofthefloatbowl.

ServiceFuelLevelAdjustment

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and donotsmoke. Makes sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

• Removethecarburetor, and drain the fuel into as suitable container.
• Removethefloatbowl.

Carburetor

- DriveoutthepivotpinAandremovethefloat[B].

- BendthetangAonthefloatarmveryslightlytochange thefloatheight.Increasingthefloatheightlowersthefuel levelanddecreasingthefloatheightraisesthefuellevel.

FloatHeight

Standard:

21.1±1mm

Technical line drawing of a mechanical clamp or bracket assembly with labeled component A (no text or symbols beyond label)

NOTE

○ FloatheightAisthedistancefromthefloatbowlmatingsurface[B]ofthecarburetorbody(withthegasket removed)tothetopofthefloat[C].Measuretheheight withthecarburetorupsidedown.
○ Donotpushtheneedlerod[D]induringthefloatheight measurement.

• Assemblethecarburetor, andrecheckthefuellevel.
  ★Ifthefu ellevelcannotbeadjustedbythismethod,the floatorthefloatvalveisdamaged.

CarburetorRemoval

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Alwaysstopthe engineanddonotsmoke.Makesuretheareais wellventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

• TurnthefueltaptotheOFFpositionandpullthefuelhose offthetap.
• Screwintheupperandlowerthrottlecableadjustersto givethecableplentyofplay(seeThrottleCableAdjustment).
• LoosenthecarburetorclampscrewsAandremovethe carburetorfromtheendoftheaircleanerduct, and then pullitoutofthecarburetorholderfromthevehicleleftside.

Close-up of a mechanical assembly with labeled component A (no readable text or symbols)

Carburetor

- UnscrewthecarburetorcapA, and pullout the throttle valve assembly[B].

NOTICE

Ifthethrottlevalveisleftattachedtothecable,wrap itinacleanclothtoavoiddamage.

- Afterremovingthecarburetor, pushaclean, lint-freetowel intothecarburetorholderandtheaircleanerducttokeep dirtorotherforeignmaterialfromentering.

WARNING

Ifdirtordustisallowedtopassthroughintothe carburetor,thethrottlemaybecomestuck,possibly causingaccident.Replaceheaircleanerelement accordingtothemaintenancechart.

NOTICE

Ifdirtgetsthroughintotheengine,excessiveenginewearandpossiblyenginedamagewilloccur.

Carburetor Installation

• Beingcarefulnottobendorotherwisedamagethejet needle, alignthegrooveAinthethrottlevalvewiththe guidepin[B]inthecarburetorbody.
  ○Checktoseethatthethrottlevalvegoesallthewaydown intothecarburetorbody, and slidessmoothly.

- FittheridgeAintothenotch[B]onthecarburetorholder.

• Tightenthecarburetorclampscrewsontheaircleaner ductandcarburetorholdersecurely.
• Routetheairventhoseandoverflowhosethroughthe clamponthecrankcase(seeCable, WireandHoseRoutingSectionintheGeneralInformationchapter).

NOTICE

Alwayskeepthehosesfreefromobstruction,and makesuretheydonotgetpinchedbythechainor shockabsorber.

Close-up of a mechanical component with labeled parts A and B, showing internal components and wiring (no readable text or symbols beyond labels)

Carburetor

- TurnthefueltaptotheONposition, and check for fuel leakage from the carburetor.

WARNING

Fuelspilledfromthecarburetorishazardous.

- Adjust the following items if necessary: Throttle Cable(seethischapter) IdleSpeed(seethischapter)

FuelInspection

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Alwaysstopthe engineanddonotsmoke.Makesuretheareais well-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

• TurnthefueltaptotheOFFposition.
• Removethecarburetor.
• Placeasuitablecontainerbeneaththecarburetor.
• RemovethedrainplugAfromthebottomofthefloat bowlandcheckforwaterordirtinthefuel.
  ★Ifanywaterordirtcomesout,cleanthecarburetor,fuel tapandfueltank(seethischapter).
• Installthedrainplugonthefloatbowl, andtightenitsecurely.
  • Installthecarburetor.

CarburetorDisassembly

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Alwaysstopthe engineanddonotsmoke.Makesuretheareais wellventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

• Removethecarburetor(seethischapter).
• Disassemblethethrottlevalveassemblyasfollows.
  ○HoldthethrottlevalvereturnspringAcompressed, take outtheretainer[B], and freethethrottlecablebyslidingit throughtheslot.

Carburetor

○Slidethejetneedleoutofthethrottlevalve.
○ PulloutthesnapringA, andremovethethrottlicable from thecarburetorcap[B].

• Disassemblethecarburetorbody.

ChokePlungerAssemblyA

IdleAdjustingScrew, SpringandO-ringB

AirScrewandSpringC

• Disassemblethecarburetorbodybottomend.

FloatBowlA

Gasket[B]

PivotPinC

Float[D]

FloatValve[E]

NeedleJet[F]

PlasticHolder[G]

PilotJet[H]

MainJet[I]

CarburetorAssembly

- Cleanthedisassembledparts(seethischapter).

NOTICE

Donotovertightenthejets. They could bedamaged requiring replacement.

• Replacethefloatbowlgasketwithanewoneifitisdeterioratedordamaged.
• BesuretoinstalltheretainerA.

Close-up mechanical assembly showing springs and components (no visible text or symbols)

Carburetor

CarburetorCleaning

WARNING

Gasolineandlow-flashpointsolventscanbe flammable and/or explosive and causes severe burns. Cleanthecarburetorinawellventilated area, and take care that there are no sparks or flame any where near the working area; this includes any appliance with a pilot light. Donot use gasoline or alow-flashpointsolvent to clean the carburetor.

• MakesurethefueltapisintheOFFposition.
• Removethecarburetor.
• Drainthefuelinthecarburetor.
• Disassemblethecarburetor.

NOTICE

Donotusecompressedaironanassembledcarburetor,thefloatmaybeformedbythepressure. Removeasmanyrubberorplasticpartsfromthe carburetoraspossiblebeforecleaningthecarburetorwithacleaningsolution.Thiswillprevent damageordeteriorationoftheparts.Donotuse astrongcarburetorcleaningsolutionwhichcould attacktheplasticparts;instead,useamildhigh flash-pointcleaningsolutionsafeforplasticparts. Donotusewireoranyotherhardinstrumentto cleancarburetorparts,especiallyjets,astheymay be damaged.

• Immerseallthemetalpartsinacarburetorcleaningsolution.
• Rinsetheparts inwater.
• Afterthepartsarecleaned, drythemwithcompressedair.
• Blowthroughtheairandfuelpassageswithcompressed air.
• Assemblethecarburetor, and installitonthemotorcycle.

CarburetorInspection

WARNING

Gasolineisextremelyflammableandcanbeexplosive under certain conditions. Always stop the engineandonotsmoke.Ma kesuretheareais well-ventilatedandfreefromanysourceofflame or sparks; this includes any appliance with a pilot light.

Carburetor

• Removethecarburetor.
• Beforedisassemblingthecarburetor, checkthefuellevel (seeFuelLevelInspection).
  ★ Ifthefuellevelisincorrect, inspecttherestofthecarburetorbeforecorrectingit.
• Pullthecarburetorcabletocheckthatthethrottlevalve Amovessmoothlyandreturnsbyspringpressure.
  ★ Ifthethrottlevalvedoesnotmovessmoothly.Replace the carburetor.
  • Disassemblethecarburetor.
• Cleanthecarburetor.

• CheckthetaperedportionAofthepilotscrew[B]for wearordamage.
  ★ Ifthepilotscrewiswornordamagedonthetaperedportion, it will prevent the engine from midlings smoothly. Replace it.

• Removethefloatvalveneedle[B].

• ChecktheplastictipAforwear.
  ★ Iftheneedleiswornasshown[C],replacethevalveneedle.

• Pushtherod[D]inthevalveneedle,thenpushandrelease[E]it.
  ★ Iftheroddoesnotcomeoutfullybyspringtension,re-placethevalveneedle.

• Removetheslowjet.

• Checktheslowjetforanydamage.
  ★ Iftheslowjetisdamaged, replaceitwithanewone.
• Removethethrottlevalveandjetneedle.
• Inspecttheoutsideofthethrottlevalveforscratchesandabnormalwear.
  ★ Ifitisbadlyscratchedorworn, replacethethrottlevalve.
• Inspecttheinsideofthecarburetorbodyforthesesame faults.
  ★ Ifitisbadlyscratchedorworn, replacetheentirecarburetor.
• Checkthejetneedleforwear.
  ★ Awornjetneedleshouldbereplaced.
• Cleanthefuelandairpassageswithahighflash-point solventandcompressedair.

AirCleaner

AirCleanerHousingRemoval

- Remove:

RadiatorShrouds

SideCovers

Seat

RearFender

RearFlap

RearFrameMountingBoltsA

RearFrame[B]

AirCleanerHousingMountingBolts[C]

- Loosentheaircleanerductclamp[D].

- Removetheaircleanerhousing[E].

AirCleanerHousingInstallation

- Installationisthereverseoftheremoval.

- Tightentherearframemountingbolts.

Torque-RearFrameMountingBolts:34N·m(3.5kgf·m,25ft·lb)

AirCleanerHousingPlateNuts:3.0N·m(0.31 kgf·m,27in·lb)

AirCleanerHousingMountingBolts:8.8N·m (0.90kgf·m,78in·lb)

ElementRemoval

- Removetheseat.

- RemovethewingboltAandpullouttheelement[B].

- Stuffaclean, lint-freetowel into the carburetor sonodirt is allowed to enter the carburetor.

- Wipeouttheinsideoftheaircleanerhousingwithaclean damptowel.

NOTICE

Checkinsideoftheinlettractandcarburetorfor dirt.lfdirtispresent,cleantheintakettractandcarburetorthoroughly.Youmayalsoneedtoreplace theelementandsealthehousingandintakettract.

ElementInstallation

- Wheninstallingtheelement,coatthelipoftheelement with a thick layer of all purpose grease A to assure a completesealagainsttheaircleanerelementbase.Also, coatthebasewherethelipoftheelementfits.

Close-up of a mechanical component with labeled parts A and B (no readable text or symbols beyond labels)

Close-up of a cylindrical mechanical component with concentric rings and a labeled section (A), being handled by a hand (no text or symbols beyond label)

AirCleaner

• InstalltheelementA.
○Theelementtab[B]positionisputonwhicheverofthe holder.

ElementCleaningandInspection

NOTE

○Industryareas, theelementshouldbecleanedmore frequentlythanrecommendedinterval.
○Afterridingthroughrainoronmuddyroads,theelement shouldbecleanedimmediately.
○Sincerepeatedcleaningopenstheporesoftheelement,replaceitwithanewoneinaccordancewiththe PeriodicMaintenanceChart. Also,ifthereisabreakin theelementmaterialoranyotherdamagetotheelement,replacetheelementwithanewone.

WARNING

Gasolineandlow-flashpointsolventscanbe flammable and/or explosive and causes severe burns. Clean the element in a well ventilated area, and take care that there is nospark or flame any-where near the working areas. Donot use gasoline or low flash points olvent st o clean the element.

• Removetheaircleanerelement, and separate the elementA from the frame[B].
• Cleantheelementinabathofahighflash-pointsolvent usingasoftbristlebrush.Squeezeitdryinacleantowel. Donotwringtheelementorblowitdry;theelementcan bedamaged.
• Checkallthepartsoftheelementforvisibledamage.
  ★ Ifanyofthepartsoftheelementaredamaged, replace them.
• Aftercleaning, saturatetheelementwithahigh-quality foam-air-filteroil, squeezeouttheexcess, thenwrapitin acleanragandsqueezeitasdryaspossible. Becareful nottotearthespongefilter.
• Assembletheelement.
• Removethetowelfromthecarburetor.
  • Installtheelement.

Two 3D-printed mechanical components with labeled parts (A and B), no visible text or symbols on the parts themselves.

FuelTank

FuelTankRemoval

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Alwaysstopthe engineanddonotsmoke.Makesuretheareais well-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

- Remove:

RadiatorShrouds

Seat

• TurnthefueltaptotheOFFposition.
• Pullthefuelhoseoffthefueltap.
• RemovethefueltankmountingboltAandband[B].
• Removethefueltank[C].
• Drainthefueltank.

FuelTankInstallation

• ChecktherubberdamperAontheframe.
  ★Ifthedamperisdamagedordeteriorated,replaceit.
• InstalltherubberdamperAnotingitsinstallingdirectionasshown.
• Besurethefuelhoseisclampedtothefueltaptoprevent leaks.
• Insertthefueltankbreatherhoseoutletendintothenumberplatehole.

FuelTapRemoval

• Removethefueltankanddrainit.
• Removethemounti ngboltsAandtakeoutthefueltap [B].

FuelTapInstallation

• BesuretheO-ringisingoodconditiontopreventleaks.
• Besuretoclampthefuelhosetothetaptopreventleaks.

FuelTank

FuelTapInspection

• Removethefueltap.
• CheckthefueltapfilterscreenAforanybreaksordeterioration.
  ★ Ifthefueltapscreenhaveanybreaksorisdeteriorated, it mayallowdirttoreachthecarburetor, causingpoorrunning. Replacethefueltap.
  ★ Ifthefueltapleaks, orallowsfueltoflowwhenitisatOFF position, replacethedamagedO-ring[B]. KX65A6F\~ [C]

FuelTankandTapCleaning

WARNING

Gasoline and low-flash points solvent scan be flammable and/or explosive and causes severe burns. Clean the tank in well-ventilated area, and take care that there are no sparks or flame any-where near the working area. Donot use gasoline or low-flash points solvent st o clean the tank.

• Removethefueltankanddrainit.
• Poursomehighflash-point solventintothefueltankand shakethetanktoremovedirtandfueldeposits.
• Pourthesolventoutofthetank.
• Removethefueltapfrom thetankbytakingoutthebolts.
• Cleanthefueltapfilterscreeninahighflash-pointsolvent.
• Pourhighflash-po intsolventthroughthetapinallever positions.
• Drythetankandtapwithcompressedair.
  • Installthetap inthetank.
  • Installthefueltank.

ReedValve

ReedValveRemoval

• RemovethecarburetorholdermountingboltsandcarburetorholderA.
• Removethereedvalve[B]outofthecylinder.

ReedValveInstallation

- Whenthereedorstoparereplaced, installthereedA andstop[B] ontothereedvalveholder[C], aligningthe chamferedcorner[D] ofthereedwiththatofthereedstop.

Torque-ReadValveScrews:9.8N·m(1kgf·m,87in·lb)

- InstallthereedvalveAandcarburetorholder[B]. - Besuretheclamp[C]isinhorizontalandtorquethecarburetorholdermountingbolts[D].

Torque-CarburetorHolderMountingBolts:8.8N·m(0.90 kgf·m,78in·lb)

ReedValveInspection

• Inspectthereedsforcracks,folds,orothervisibledamage.
  ★ If there is any doubt to the condition of areed, replace thereof valve part with anewone.
  ★lfareedbecomeswavy,replacethevalvepartwithanew oneevenifitswarpislessthantheservicelimit.
• Measure the clearance between thereedA and holder [B], and check thereed warpasshown.
  ★ Ifanyoneoftheclearancemeasurementsexceedsthe servicelimit,replacevalvepartwithanewone.

ReedWarp

ServiceLimit: 0.5mm

FuelHose

FuelHosesandConnectionsCheck

○ Checkthefuelhoseperiodicallyinaccordancewiththe PeriodicMaintenanceChart, and ifthemotorcycle is not properly handled, the insidethefuelline can cause fuel to leak A or the hosetoburst. Removethefueltank and checkthefuelhose.

★Replacethefuelhoseifanyfraying,cracks[B]orbulges [C]arenoticed.

- Check that the hoses are securely connected and clamps are tightened correctly.

- Wheninstalling, routethehosesaccordingtoCable, Wire and HoseRoutingsectionintheGeneralInformation chapter.

- Wheninstallingthefuelhoses, avoidsharpbending, kinking, flatteningortwisting, and routethefuelhoses with a minimumofbendingsothatthefuelflowwillnotbeobstructed.

★Replacethehoseifithasbeensharplybentorkinked.

CoolingSystem

TableofContents

Exploded View.... 3-2

Specifications 3-3

Coolant 3-4

Coolant Level Inspection.... 3-4

Coolant Deterioration Inspection.... 3-4

Coolant Draining 3-5

Coolant Filling 3-5

Air Bleeding.... 3-6

Cooling System Pressure Testing 3-6

Cooling System Flushing 3-7

DisassemblyandAssemblyPrecautions....3-8

Water Pump 3-9

Water Pump Cover Removal 3-9

Water Pump Cover Installation 3-9

Impeller Removal 3-9

Impeller Installation 3-9

Impeller Inspection 3-9

Water Pump Shaft Removal 3-10

Water Pump Shaft Installation 3-10

Oil Seal Removal 3-10

Oil Seal Installation 3-10

Radiator 3-12

Radiator Removal 3-12

Radiator Installation 3-12

Radiator Inspection 3-12

Cap Inspection 3-13

Filler Neck Inspection.... 3-13

WaterHoses,BreatherHoseInspection....3-13

WaterHoses,BreatherHoseInstallation....3-13

GD02073BW4 C

1. Radiator
   2.RadiatorCap
2. WaterPumpCover
   4.DrainPlug
   5.Impeller
   6.OilSeal(Short)
   7.OilSeal(Long)
   8.Bearing
   9.WaterPumpGear
   10.RightEngineCover

11.CylinderHead

12.Cylinder

13.AirBleederBolt

T1:8.8N·m(0.90kgf·m,78in·lb)

T2:8.3N·m(0.85kgf·m,73in·lb)

T3:5.9N·m(0.60kgf·m,52in·lb)

T4:1.5N·m(0.15kgf·m,13in·lb)

G:Applygrease.

M:Applymolybdenumdisulfidegrease.

Specifications

ItemStandard
CoolantTypeColorGreenMixedratioTotalamount0.4L	PermanenttypeantifreezeforaluminumenginesandradiatorsSoftwater50%,coolant50%
RadiatorCap relief pressure	108 ~ 137 kPa (1.1 ~ 1.4 kgf/cm2, 16 ~ 20 psi)

SpecialTools-BearingDriverSet:57001-1129

OutsideCirclipPliers:57001-144

3-4COOLINGSYSTEM

Coolant

Check the coolant level each day before riding the motor-cycle, and replenish coolant if the level is slow. Changethe coolant in accordance with the Periodic Maintenance Chart (see General Information chapter).

WARNING

Hotenginecoolantcancauseseriousburns. To avoidburns, donotremovetheradiatorcaportry toinspectthecoolantlevelorchangethecoolant whentheengineisstillhot. Waituntilcoolsdown.

CoolantLevelInspection

NOTE

○Checkthelevelwhentheengineiscold(roomorambienttemperature).

• Situatethemotorcyclesothatisperpendiculartothe ground.
• RemovetheradiatorcapA.

NOTE

○Removetheradiatorcapintwosteps.Firstturnthe capcounterclockwisetothefirststopandwaittherefor afewseconds.Thenpushdownandturnitfurtherin thesamedirectionandremovethecap.

• Checkthecoolantlevel.ThecoolantlevelAshouldbe atthebottomofthefillerneck[B].
  ★ Ifthecoolantlevelislow, addcoolantthroughthefiller openingtothebottomofthefillerneck.Installthecap.

RecommendedCoolant:

Permanent type of antifreeze (softwater and ethylene glycol plus corrosion and trustinhibitor chemicals for aluminum engines and radiators)

WaterandCoolantMixtureRatio:

1:1(water50%,Coolant50%)

Totalamount:0.4L

Close-up of a mechanical component with a labeled section A pointing to a circular feature (no readable text or symbols)

CoolantDeteriorationInspection

• Visuallyinspectthecoolant.
  ★ Ifwhitishcotton-likewaftsareobserved,aluminumparts inthecoolingsystem arecorroded. Ifthecoolantis brown,ironorsteelpartsarerusting.Ineithercase,flush thecoolingsystem.
  ★ Ifthecoolantgivesoffanabnormalsmell, checkfora coolingsystemleak. It may be caused by exhaust gas leaking into the coolingsystem.

Coolant

CoolantDraining

Thecoolantshouldbechangedperiodicallytoensure longenginelife.

WARNING

Coolantcanbeextremelyhotandcausesevere burns,istoxicandveryslippery.Donotremove theradiatorcaporattempttochangethecoolant whentheengineishot;allowitcoolcompletely. Immediatelywipeanyspilledcoolantfromtires, frame,engineorotherpaintedparts.Donotingest coolant.

- Removetheradiatorcap.

NOTE

○Removetheradiatorcapintwosteps.Firstturnthe capcounterclockwisetothefirststopandwaittherefor afewseconds.Thenpushdownandturnitfurtherin thesamedirectionandremovethecap.

• PlaceacontainerunderthecoolantdrainplugA, and drainthecoolantfromtheradiatorandenginebyremovingthedrainplugonthewaterpumpcover.Immediately wipeorwashoutanycoolantthatspillsontheframe,engine,orwheel.
• Inspecttheoldcoolantforvisualevidenceofcorrosion andabnormalsmell(seeCoolantDeteriorationInspection).

CoolantFilling

NOTICE

Usecoolantcontainingcorrosioninhibitorsmade specificallyforaluminumenginesandradiatorsin accordancewiththeinstructionofthemanufac-turer.Softordistilledwatermustbeusedwiththe antifreeze(seebelowforantifreeze)inthecooling system.Ifhardwaterisusedinthesystem,it causescaleaccumulationinthewaterpassages, and considerably reduces the efficiency of the coolingsystem.

RecommendedCoolant

Type:

Permanenttypeantifreeze(soft waterandethyleneglycolplus corrosionandrustinhibitor chemicalsforaluminumengines andradiators)

Color: Green
MixedRatio: Softwater50%,Coolant50%
FreezingPoint: -35^(-31^)
TotalAmount: 0.4L

• Installthecoolantdrainplug.

○Replacethegasketwithanewone.

Torque- CoolantDrainPlug(WaterPump):8.8N·m(0.90 kgf·m,78in·lb)

Close-up mechanical component with labeled section A (no readable text or symbols beyond label)

Coolant

- Filltheradiatoruptothebottomoftheradiatorfillerneck [B]withcoolantA,andinstallthecap,turningitclockwise about1/4turn.

NOTE

○Pourinthecoolantslowlysothatitcanexpeltheair fromtheengineandradiator. Theradiatorcapmustbe installedintwosteps.Firstturnthecapclockwisetothe firststop.Thenpushdownonitandturnittherestof theway.

- Checkthecoolingsystemforleaks.

AirBleeding

- Bleedtheairfromthecoolingsystemasfollows.

○LoosentheairbleederboltAonthecylinderheaduntil thecoolantbeginstoflowouttheairbleederbolthole(that is,untilalltheremainingairhasbeenforcedout).

○ Tightentheairbleederbolt.

Torque-AirBleederBolt:8.8N·m(0.90kgf·m,78in·lb)

○ Starttheengine withtheradiatorcapremovedandrunit untilnomoreairbubblesAcanbeseeninthecoolant.
○Tapthecoolinghosestoforceanyairbubblescaught inside.
○Stoptheengineandaddcoolantuptothefillerneck.
- Checkthecoolingsystemforleaks.
• Installtheradiatorcap.
○ Theradiatorcapmustbeinstalledintwosteps.Firstturn thecapclockwisetothefirststop.Thenpushdownonit andturnittherestoftheway.

CoolingSystemPressureTesting

NOTICE

Duringpressuretesting, donotexceedthepres- sureforwhichthesystemisdesignedtowork. The maximumpressureis123kPa(1.25kgf/cm², 18psi).

- Removetheradiatorcap, and installacoolingsystem pressuretesterAandadapter[B]ontheradiatorfiller neck[C].

NOTE

○Wettheadaptercapsealingsurfaceswithwateror coolanttopreventpressureleaks.

• Builduppressureinthesystemcarefullyuntilthepressurereaches123kPa(1.25kgf/cm²,18psi).
• Watchthegaugeforatleast6seconds.Ifthepressure holdssteady,thecoolingsystemisallright.
• Removethepressuretester,replenishthecoolant,and installtheradiatorcap.
  ★ If the pressuredrops and no external source is found, check for internal leaks. Check the cylinder headgasket for leaks.

Close-up of a mechanical component with labeled parts (A and 9134), no readable text or symbols beyond labels

Coolant

CoolingSystemFlushing

Overaperiodoftime, thecoolingsystem accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the coolingsystem. If this accumulation is not removed, it will clog up the water passages and considerably reduce the efficiency of the coolingsystem.

• Drainthecoolingsystem.
• Fillthecoolingsystemwithfreshwatermixedwithaflushingcompound.

NOTICE

Avoidtheuseofaflushingcompoundwhichis harmfultothealuminumengineandradiator. Carefullyfollowtheinstructionssuppliedbythe manufacturerofthecleaningproduct.

• Warmuptheengine, and runitat normal operating temperature for about ten minutes.
• Stoptheengine, and drain the coolingsystem after the coolant cools down.
• Fillthesystemwithfreshwater.
• Warmuptheengineanddrainthesystemafterthe coolantcoolsdown.
• Repeat the previous wostepsoncemore.
• Fillthesystemwithapermanenttypecoolant,andbleed theairfromthesystem(seeAirBleeding).

3-8COOLINGSYSTEM

Disassembly and Assembly Precautions

• Priorodisassemblyofcoolingsystemparts(radiator, pump,etc),waituntilhecoolantcoolsdown,andthen drainthecoolant.
• Afterassembling and filling the system with coolant, bleed any air from the system.

WaterPump

Water Pump Cover Removal

• Drain the coolant (see Coolant Draining).
• Loosen the water hose clamps A, and disconnect the water hoses on the water pump cover [B].
• Unscrew the cover bolts [C], and remove the water pump cover.

Water Pump Cover Installation

• Replace the pump cover gasket with a new one.
  ● Tighten the water pump cover bolts and clamps.

Torque-WaterPumpCoverBolts:8.8N·m(0.90kgf·m,78in·lb)

• Fill the cooling system (see Coolant Filling).
• Bleed the air from the cooling system.

Impeller Removal

• Drain the coolant (see Coolant Draining).
• Remove the cover bolts and take out the water pump cover from the 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-WaterPumplm pellerBolt:8.3N·m(0.85kgf·m,73 in·lb)

Impeller Inspection

● Visually check the impeller A.
★If the surface is corroded, or if the blades [B] are damaged, replace the impeller.

WaterPump

WaterPumpShaftRemoval

• Remove:
  RightEngineCover(seeEngineRightSidechapter)
• RemovethecirclipA, and pulloff the primary gear[B]. Special Tool - Outside Circlip Pliers: 57001-144

KX65A6F\~:

• RemovetheprimarygearB.
• Pulloutthewaterpumpshaft[C]towardinsideoftheright enginecover.

WaterPumpShaftInstallation

- Topreventtheoilseallipsfrompeeling,applyamolybdenumdisulfidegreaseAtothewaterpumpshaft[B]and insertitintotheoilseals[C]fromtheinsideoftheright enginecover[D].

NOTICE

Besuretoapplyamolybdenumdisulfidegrease tothewaterpumpshaftwheninstalling.Ifitisinstalleddry,thesealsmaywearexcessively.

• Replacethecirclipfortheprimarygearwithanewone.
  SpecialTool-OutsideCirclipPliers:57001-144
• Instaltheimpellerandchecktoseethattheimpellerturn freely.

OilSealRemoval

• Remove:
  Impeller(seethischapter)
  RightEngineCover(seeEngineRightSidechapter)
• Toremovetheoilseals. Insertametalrodintotheright enginecoverfromtheoppositesideoftheimpeller, and tapevenlyaroundthebottomoftheseal.
  AMetalRod
  [B]OilSeals
  [C]Tap
  [D]BallBearing

OilSealInstallation

NOTICE

If the oil seal or ball bearing is removed, replace all of them with new ones at the same time

- Besuretoreplacetheoilseals.

WaterPump

• PresstheballbearingAintotheholeuntilthebearingis bottomedagainstthestep[B].
  SpecialTools-BearingDriverSet:57001-1129
• Applyplentyofhightemperaturegreasetotheoilseallips [D].
• Settheoilseal(thick)sothatduallipssidefaceoutward andsettheoilseal(thin)sothatalipfacesoutwardas shown.
• Presstheoilseals[E]intotheholeuntiltheoilsealis bottomedagainsttheballbearingortheseal.
  SpecialTools-BearingDriverSet:57001-1129[C]
  ○Theendoftheoilsealmustbe0.5±0.2mm[F]lower thantheendoftherightenginecoverend[G].
  ○BesuretheinnerraceoftheballbearingAturns smoothly.

Radiator

RadiatorRemoval

• Drainthecoolant(seeCoolantDraining).
• Remove:

LeftShroudA

WaterHose[B]

RadiatorMountingBolts[C]

RadiatorScreen[D]

BreatherHose

Radiator[E]

RadiatorInstallation

• Radiatorinstallationisthereverseofremoval.
• Routethewaterandbreatherhosescorrectly.

Torque-RadiatorMountingBolts:8.8N·m(0.90kgf·m,78in·lb)

ShroudMountingBolts:8.8N·m(0.90k gf·m,78

in·lb)

RadiatorInspection

• Checktheradiatorcore.
  ★ If there are obstruction to airflow, removethem.
  ★ Ifthecorrugated finsaredeformed, carefully straighten them with the thin blade of ascrewdriverA.

NOTICE

Donotteartheradiatortubeswhilestraightening thefins.

★ If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably deformed fins, replacetheradiator with anewone.

NOTICE

Whencleaningtheradiatorwithasteamcleaner,be carefulofthefollowingtopreventradiatordamage. Keepthesteamgun[C]awaymorethan0.5m[B] fromtheradiatorcore.Holdthesteamgunperpendicularartothecoresurface.RunthesteamgunfollowingthecorefindirectionA.

Close-up of a car radiator grille with a tool inserted, no visible text or symbols

Radiator

CapInspection

• Checktheconditionofthevalvespring[B], andthetop andbottomvalvesealsA oftheradiatorcap.
  ★Ifanyoneofthemshowsvisibledamage,replacethecap.

• Wetthetopandbottomvalvesealswithwaterorcoolant topreventpressureleaks.
• InstallthecapAonacoolingsystempressuretester[B].
• Watching the pressure gauge, slowly pump the pressure testertobuildup the pressure. The gauge hand must remain within the relief pressurer range in the table below at least 6 seconds. Continuetopump the tester until the relief valve opens, indicated by the gauge hand flicking downward. There relief valve must open within the specified range.

RadiatorCapReliefPressure:

Standard: 108 \~ 137 kPa (1.1 \~ 1.4 kgf/cm², 16 \~ 20 psi)

★ Ifthecapcannotholdthepressure, orifthereliefpressure istoohighortoolow, replacethecapwithanewone.

FillerNeckInspection

• Checktheradiatorfillerneckforsignsofdamage.
• Checktheconditionofthetopandbottomsealingseats Ainthefillerneck. They must besmoothandcleanfor theradiatorcaptofunctionproperly.

Technical line drawing of a mechanical component with labeled part A (no text or symbols beyond label)

WaterHoses, BreatherHoseInspection

• InaccordancewiththePeriodicMaintenanceChart, visuallyinspectthehosesAforsignsofdeterioration. Squeezethehose.Ahoseshouldnotbehardandbrittle, norshoulditbesoftorswollen.
• Replaceanydamagedhose.

Close-up of mechanical components with labeled parts (A), no readable text or symbols present

WaterHoses, Breather Hose Installation

• Installthewaterhosesorbreatherhosebeingcareful tofollowtheperformedbends(seeGeneralInformation chapter). Avoid sharp bending, kinking, flattening, or twisting.
• Tightenthehoseclampssecurely.

EngineTopEnd

TableofContents

Exploded View.... 4-2

Specifications 4-3

Cylinder Head 4-4

CylinderCompressionMeasurement....4-4

Cylinder Head Removal 4-4

Cylinder Head Installation 4-5

Cylinder Head Warp Inspection 4-5

Cylinder 4-6

Cylinder Removal 4-6

Cylinder Installation 4-6

Piston Removal 4-6

Piston Installation 4-7

Cylinder Wear Inspection 4-8

Piston Diameter Measurement 4-8

Piston/CylinderClearanceInspection....4-8

PistonRing, Piston Ring Groove Inspection....4-9

Piston Ring End Gap Inspection 4-9

Piston, PistonPin, ConnectingRodWearInspection....4-10

Muffler (Expansion Chamber) 4-11

Muffler Removal 4-11

Muffler Installation 4-11

Muffler Baffle Replacement.... 4-11

1.SparkPlug
2.CylinderHead
3.Cylinder
4. PistonRing
5."1N"Mark
6."2N"Mark
7. Piston
8."IN"Mark
9.PistonPin
10.ExpansionChamber
11.RubberSeal

12.Gasket
13.MufflerBody(KX65-A1\~A2)
T1:25N·m(2.5kgf·m,18ft·lb)
T2:5.9N·m(0.60kgf·m,52in·lb)
T3:26N·m(2.6kgf·m,19ft·lb)
T4:8.8N·m(0.90kgf·m,78in·lb)

L:Applyanon-permanentlockingagent.

M:Applymolybdenumdisulfidegrease.

O:Apply2-strokeengineoil.

SS:Applysiliconesealant.

Specifications

ItemStandardServiceLimit
CylinderHeadCylinderCompression(Usablerange)– –Cylinderheadwarp– – – 0.03mm	–755 ~ 1 177 kPa (7.70 ~ 12.0 kgf/cm2, 109~ 171psi)
Cylinder,PistonCylinderInsideDiameter(15mmbelow fromtheCylinderTopEnd)Piston DiameterPiston/Cylinder ClearancePistonRing/GrooveClearance(Top, Second)PistonRingGrooveWidth(Top, Second)Piston Ring Thickness (Top, Second)Piston Ring End Gap (Top, Second)Piston Pin DiameterPiston Pin Hole DiameterSmallEndInsideDiameter	44.500~ 44.515mm44.64mm44.453 ~ 44.468 mm0.042 ~ 0.052 mm0.02 ~0.06 mm1.01 ~ 1.03 mm0.97 ~ 0.99 mm0.15 ~ 0.35 mm11.995 ~ 12.000 mm12.001 ~ 12.011 mm16.002~ 16.013mm16.05mm	44.30 mm–– –0.16 mm1.11 mm0.90 mm0.65 mm11.96 mm12.08 mm

SpecialTool- PistonPinPullerAssembly:57001-910

CylinderHead

CylinderCompressionMeasurement

• Starttheengine.
• Thoroughlywarmuptheenginesothattheengineoilbetweenthepistonandcylinderwallwillhelpsealcompressionasitdoesduringnormalrunning.
• Stoptheengine.
• Removethefueltank(seeFuelSystemchapter).
• Removethesparkplug, andscrewacompressiongauge firmlyintothesparkplughole.

NOTE

Useacompressiongaugecommerciallyavailable.It's impossibletoinstallastheframewillinterferewiththe operationifusingKAWASAKIspecialtools(PN:57001-221&57001-1159).

- Withthethrottlefullyopen,turntheengineoversharply withthekickstarterseveraltimesuntilthecompression gaugestopsrisingthecompressionisthehighestreading obtainable.

CylinderCompression

UsableRange:

755 \~ 1 177 kPa (7.70 \~ 12.0

• LayastraightedgeAacrossthelowersurfaceofthe headatseveraldifferentpoints,andmeasurewarpby insertingathicknessgauge[B]betweenthestraightedge andthehead.
  ★Ifwarpexceedstheservicelimit,repairthematingsurface.Replacethecylinderheadifthematingsurfaceis badlydamaged.

CylinderHeadWarp

Standard: 0.03mm

Cylinder

CylinderRemoval

• Drainthecoolant(seeCoolingSystemchapter).
• Remove:

CylinderHead(seethischapter)

Carburetor(seeFuelSystemchapter)

WaterHoseUpperEnd

ClutchCableLowerEnd

MufflerHoldingSprings

• RemovethecylindernutsA.
• Liftoffthecylinder[B], andremovethecylinderbasegasket. If necessary, taplightlyaroundthebaseofthecylinderwithaplasticmallet, takingcarenottodamagethe cylinder.

CylinderInstallation

• Scrapeanycarbonoutoftheexhaustport.
• Checkonacrustofmineralsandrustinthecylinderwater jacket,andremovethemifnecessary.
• Replacethecylinderbasegasketwithanewone.
• Applyengineoiltothepistonsurface, pistonringsand cylinderbore.
• ChecktoseethatthepinAineachpistonringgroove isbetweentheendsofthepistonring,andfitthebaseof thecylinderovereachring,pressinginonoppositesides oftheringasnecessary.Becertainthattheringsdonot slipoutofposition.
• Tightenthecylindernutsdiagonally.

Torque-CylinderNuts:25N·m(2.5kgf·m,18ft·lb)

PistonRemoval

• Removethecylinder.
• Stuffacleanclothintothecrankcaseopeningaroundthe connectingrodsothatnopartswillfallintothecrankcase.
• Removeoneofthepistonpinsnapringswithneedlenose pliers.
• Removethepistonbypushingthepistonpinouttheside fromwhichthesnapringwasremoved.Useapistonpin pullerassemblyA,ifthepinistight.

SpecialTools- PistonPinPullerAssembly:57001-910

• Removethepistonring(s).
  ○ CarefullyspreadtheringAopeningwithyourthumbs and thenpushupontheoppositesideoftheringtore-moveit.

Close-up of a mechanical assembly with labeled component A, showing mechanical components and wiring (no readable text or symbols)

Cylinder

PistonInstallation

• Stuffacleanclothintothecrankcaseopeningaroundthe connectingrodsothatnopartswillfallintothecrankcase.
• Scrapeoffanycarbonofthepiston, then lightly polish the pistonwithfineemerycloth.
• Cleancarbonanddirtoutofthepistonringgrooveusing asuitabletool.

NOTICE

Carbonparticlescanbeveryabrasivetopiston ring. Don't allowsuch particlestofallontothe cylinderwalls.

• Wheninstallingthepistonringonthepiston,notethefollowing:
  ○Firstfitoneendofthepistonringagainstthepinintheringgroove, spreadtheringopeningwiththeotherhand andthensliptheringintothegroove.
  ○Thetopringhavea“1N”markAonitsuppersurface.
  ○Thesecondringhavea“2N”mark[B]onitsuppersurface.

○InstalltheringsothatthepinAinthepistonringgroove isbetweentheendsofthepistonring.

• Apply2-strokeengineoiltotheconnectingrodneedle bearingandthepistonpin.
• InstallthepistonAsothatthe"IN"markedside[B]faces theback(intake)sideoftheengine.

- WheninstallingapistonpinsnapringA, compressitonly enoughtoinstallitandnomore.

NOTICE

Donotreusesnaprings,asremovalweakensand deformsthem.Theycouldfalloutandscorethe cylinderwall.

- Fitanewpistonpinsnapringintothesideofthepistonso thattheringopening[B]doesnotcoincidewiththenotch [C]intheedgeofthepistonpinhole.

Cylinder

CylinderWearInspection

NOTE

○Measurethecylinderinsidediameterwhenthecylinder iscold(roomorambienttemperature).

• VisuallyInspecttheinsideofthecylinderforscratches andabnormalwear.
  ★ Ifthecylinderisdamagedorbadlyworn,replaceitwitha newone.
• Sincethereisadifferenceincylinderwearindifferentdirections, takeaside-to-sideandafront-tobackmeasurementshowninthefigure.
  ★ Ifanyofthecylinderinsidediametermeasurementsexceedstheservicelimit, thecylindermustbereplacedwith anewonesincetheELECTROFUSIONcylindercannot beboredorhoned.

CylinderInsideDiameter

Standard: 44.500\~44.515mm, and less than 0.01 mmdifference between any two measurements.

ServiceLimit: 44.64mm,ormorethan0.05 mmdifferencebetweenanytwo measurements.

PistonDiameterMeasurement

• Measuretheoutsidediameter[B]ofthepiston6. 0 mm Aupfromthebottomofthepistonatarightangletothe directionofthepistonpin.
  ★ Ifthemeasurementisundertheservicelimi t,replace the piston.

PistonDiameter

Standard: 44.453\~44.468mm

ServiceLimit: 44.30mm

Piston/CylinderClearancelnspection

Thepiston-to-cylinderclearanceismeasuredwhenevera pistonorcylinderisreplacedwithanewone. Thestandard piston-to-cylinderclearancemustbeadheredtowhenever thecylinderisreplaced.

Ifonlyapistonisreplaced, the clearancemayexceed the standardslightly. Butitmustnotbelessthantheminimum, inordertoavoidpistonseizure.

Thermostaccuratewaytofindthepistonclearanceis bymakingseparatepistonandcylinderdiametermeasurementsandthencomputingthedifferencebetweenthetwo values.Measurethepistondiameterasjustdescribed,and measurethecylinderdiameterattheverybottomofthe cylinder.

Piston/CylinderClearance

Standard: 0.042\~0.052mm

Cylinder

PistonRing, PistonRing Groove Inspection

• Visually inspect the piston rings and the piston ring grooves.
  ★Iftheringsarewornunevenlyordamaged,theymustbe replaced.
  ★Ifthepistonringgroovesarewornunevenlyordamaged, thepistonmustbereplacedandfittedwithnewrings.
• Checkforunevengroovewearbyinspectingtheringseating.
• Theringsshouldfitperfectlyparalleltothegroovesurfaces.Ifnot,thepistonmustbereplaced.
• With the piston ring in its groove, makes several measurements with a thickness gauge A to determine piston ring/groove clearance.
  ★ If the clearance exceed stheservicelimit, measure the thickness of the piston ring
  ★Iftheringhasworndowntolessthantheservicelimit, replacethering;ifthegroovewidthexceedstheservice limit,replacethepiston.

PistonRing/GrooveClearance(Top, Second)

Standard: 0.02\~0.06mm

ServiceLimit: 0.16mm

PistonRingThickness(Top,Second)

Standard: 0.97\~0.99mm

ServiceLimit: 0.90mm

PistonRingGrooveWidth(Top,Second)

Standard: 1.01\~1.03mm

ServiceLimit: 1.11mm

PistonRingEndGapInspection

• PlacethepistonringAinsidethecylinder[B], using the pistontolocatetheringsquarelyinplace.
• Setitclosetothebottomofthecylinder, wherecylinder wearislow.
• Measurethegap[C]betweentheendsoftheringwitha thicknessgauge.
  ★Ifthegapiswiderthantheservicelimit,theringisover-wornandmustbereplaced.

PistonRingEndGap(Top, Second)

Standard: 0.15\~0.35mm

ServiceLimit: 0.65mm

Cylinder

Piston, PistonPin, ConnectingRodWear Inspection

• VisuallyinspectthesnapringAstillfittedinplace.
  ★ Iftheringshowsweaknessordeformation, replacethering. Also if the pinhole grooveshowsexcessive wear, replacethepiston.
• Measurethediameterefthepistonpin[B]withamicrometer.
  ★ Ifthepistonpindiameterislessthantheservicelimitat anypoint, replacethepistonpin.
• Usingacylindergauge, measurethediameterofbothof pistonpinholes[C]inthepistonandtheinsidediameter oftheconnectingrodsmallend.
  ★ Ifeitherpistonpinholediameterexceedstheservicelimit, replacethepiston.
  ★ If the connecting rod small ends in diameter exceeds the servicelimit, replacethe crankshaft assembly.
• Checktheneedlebearing[D].
  ○ Therollersinaneedlebearingnormallywearverylittle, andwearisdifficulttomeasure.Insteadofmeasuring, inspectthebearingforabrasion,colorchange,otherdamage.
  ★ Ifthereisanydoubtastotheconditionofaneedlebearing,replacethebearingandpistonpin.

PistonPinDiameter

Standard: 11.995\~12.000mm

ServiceLimit: 11.96mm

PistonPinHoleDiameter

Standard: 12.001\~12.011mm

ServiceLimit: 12.08mm

SmallEndInsideDiameter

Standard: 16.002\~16.013mm

ServiceLimit: 16.05mm

Muffler(ExpansionChamber)

MufflerRemoval

- Remove:

RightShroud

RightSideCover

- Removethemufflermountingbolts[B]andpullthemufflerAofftowardtherear.

- RemovethespringsAholdingtheexhaustpipeholding

- Removetheexpansionchamberdampermountingbolts A, and pullofftheexpansionchambertotheforward.

- Removetheexhaustgasket.

MufflerInstallation

- Scrapeanycarbonoutoftheexpansionchamber.

- ChecktheexhaustO-ringsforsignsofdamage.

★Ifnecessary, replacethemwithnewones.

- InstallthespringsAholdingtheexhaustpipesothattheir fixedhooks[B]facethecylinder.

Torque-MufflerMountingBolts:8.8N·m(0.90kgf·m,78in·lb)

ExpansionChamberDamperMountingBolt, Nut: 8.8 N·m (0.90 kg f·m, 78 in·lb)

MufflerBaffleReplacement

Replacethemufflerbaffleifexhaustnoisebecomestoo loudortheengineperformedrops.

- RemovethemufflerpipeboltsA, and pull themuffler pipe[B] from themufflerbody.

- Removethemuffler.

Close-up of mechanical components with springs and a labeled section (A), no readable text or symbols present.

Close-up of a mechanical assembly with labeled component A (no readable text or symbols beyond label)

4-12ENGINETOPEND

Muffler(ExpansionChamber)

• UnscrewtheinnerpipemountingboltsA.

• Pulltheinnerpipe[B]fromthemufflerbody.

• Pullofftheoldmufflerbaffle, and install thenewmuffler baffleAintothemufflerbody.

• Applysiliconesealanttothecircumference[B]oftheinner pipe.
• Applyanon-permanentlockingagenttotheinnerpipe mountingbolts.
  • Installthemuffler.

Torque-InnerPipeMountingBolts:5.9N·m(0.6kgf·m,52in·lb)

EngineRightSide

TableofContents

Exploded View.... 5-2

Specifications 5-4

Clutch Cable 5-5

Clutch Lever Free Play Inspection 5-5

Free Play Adjustment.... 5-5

Clutch Cable Removal 5-6

Clutch Cable Installation 5-6

ClutchCableLubricationandInspection......5-6

Right Engine Cover 5-7

Right Engine Cover Removal 5-7

Engine Right Cover Installation.... 5-7

RightEngineCoverDisassembly 5-9

Right Engine Cover Assembly 5-9

Clutch 5-10

Clutch Removal 5-10

Clutch Installation.... 5-10

Friction and Steel Plates Wear, Damage Inspection.... 5-11

Friction and Steel Plate Warp Inspection 5-11

SpringFreeLengthMeasurement....5-12

FrictionPlate/ClutchHousingClearanceInspection....5-12

Clutch Hub Spline Inspection.... 5-12

External Shift Mechanism.... 5-13

External Shift Mechanism Removal 5-13

External Shift Mechanism Installation 5-13

External Shift Mechanism Inspection.... 5-13

Primary Gear 5-14

Primary Gear Removal 5-14

Primary Gear Installation 5-14

Primary Gear Removal (KX65A6F \~) 5-14

Primary Gear Installation (KX65A6F \~) 5-14

Kickstarter 5-16

Kickshaft Removal 5-16

Kickshaft Installation 5-16

Kickstarter Assembly Disassembly/Assembly 5-16

Idle Gear Removal 5-16

Idle Gear Installation 5-16

ExplodedView

1. ClutchLever
2. ClutchCable
3. Release Lever Shaft
4. ClutchPusher
   5.Shim(s)
   6.SpringPlatePusher
5. ClutchHub
6. ClutchWheel

7. FrictionPlate

8. SteelPlate

9. ClutchHousing

12.Sleeve

13.PrimaryGear

14.GearSetLevers

15.ShiftShaft

16.KickstarterIdleGear

17.RatchetGear

18.KickGear

19.KickShaft

20.KX65-A1\~A6

T1:8.8N·m(0.90kgf·m,78in·lb)

T2:64N·m(6.5kgf·m,47ft·lb)

T3:9.3N·m(0.95kgf·m,82in·lb)

T4:5.2N·m(0.53kgf·m,46in·lb)

T5:1.5N·m(0.15kgf·m,13in·lb)

T6:49N·m(5.0kgf·m,36ft·lb)

T7:12N·m(1.2kgf·m,104in·lb)

EO:ApplyEngineoil.

G: Apply hight temperature grease.

Lh:Left-handThreads

M:Applymolybdenumdisulfidegrease.

O:Applyoil.

Specifications

Item	StandardServiceLimit
Clutch
Lever Free Play	8 ~ 13 mm	---
FrictionPlateThickness3.1~ 3.3mm2.9mm
Steel Plate Thickness	1.47 ~ 1.73 mm	1.37 mm
FrictionPlateWarpNotmorethan0.2mm0.3mm
SteelPlateWarp	Notmorethan0.15mm0.3mm
ClutchSpringFreeLength28.1mm26.7mm
Friction Plate/Clutch Housing Clearance	0.3 ~ 0.6 mm	0.9 mm

Special Tools - Flywheel & Pulley Holder: 57001-1605
OutsideCirclipPliers: 57001-144

ClutchCable

Duetofrictionplatewearandclutchcablestretchchover alongperiodofuse,theclutchmustbeadjustedinaccordancewiththePeriodicMaintenanceChart.

WARNING

Theengineandexhaustsystemgetextremelyhot duringnormaloperationandcancauseserious burns.Nevertouchtheengineorexhaustpipe duringclutchadjustment.

ClutchLeverFreePlayInspection

• SlidetheclutchleverdustcoverAoutofplace.
• Check that the clutch cable upper end is fully seated in the adjuster[B].
• Check that the clutch lever [C] has 8 \~ 13 mm of play [D].
  ★ Ifitdoesnot,adjusttheleverplay.

FreePlayAdjustment

• Slidetheclutchleverdustcoveroutofplace.
• LoosentheknurledlocknutA.
• Turntheadjuster[B]sothattheclutchleverwillhave8\~13mmofplay.

NOTE

Besurethattheoutercableendattheclutchleveris fullyseatedintheadjusterattheclutchlever,oritcould slipintotheplacelater,creatingenoughcableplayto preventclutchdisengagement.

• Tightenthelocknut .
• Ifitcannotbedone,loosentheadjustingnutsAatthe bottomoftheclutchcable,andturnthenutssothatclutch leverhas8\~ 13mmofplay.
• After the adjustment is made, tighten the locknut, and starttheengineandcheckthattheclutchdoesnotslip andthatitreleaseproperly.

Close-up of mechanical components with no visible text or symbols

ClutchCable

ClutchCableRemoval

• Slidethedustcoveroutofplace.
• Loosentheadjustingnutsatthelowerofthecable, and turntheadjustingnutstogivethecableplentyofplay.
• LoosentheknurledlocknutAattheclutchlever, and screwintheadjuster[B].
• Lineuptheslots[C]intheclutchlever,knurledlocknut, andadjuster,andthenfreethecablefromtheclutchlever.

- Freetheclutchinnercabletipfromtheclutchrelease lever.

NOTICE

Donotremovetheclutchreleaseshaftunlessitis absolutelynecessary.Ifremoved,releaseshaftoil sealmustbereplacedwithanewone.

- Pulltheclutchcableoutoftheframe.

ClutchCableInstallation

• RuntheclutchcableaccordingtotheCable, Wire and HoseRoutingsectionoftheGeneralInformationchapter.
• Adjusttheclutchcable(seeFreePlayAdjustment).

ClutchCableLubricationandInspection

• LubricatetheclutchcableAusingthepressurecable lubberinaccordan cewiththePeriodicMaintenance Chart.
• Withthecabledisconnectedatbothends, thecable shouldmovef reelywithinthecablehousing(seeAppendixchapter).

Line drawing of hands holding a syringe with a labeled component (A), no text or symbols present

RightEngineCover

RightEngineCoverRemoval

• Draintheengineoil(seeEngineOilChangeintheEngine BottomEnd/Transmissionchapter).
• Drainthecoolant(seeCoolantDrainingintheCooling Systemchapter).
• Remove:

WaterHoseLowerEnds

KickPedal

ClutchCableLowerEnd(seethischapter)

BrakePedal

WaterPumpImpeller(seeCoolingSystemchapter)

• Removetherightenginecovermountingbolts.
• TurntheclutchreleaseleverAtowardtherearandremovetherightenginecover[B].

EngineRightCoverInstallation

- ApplymolybdenumdisulfidegreaseAtothewaterpump shafttopreventwaterpumpsealdamage.

NOTICE

Iftherightenginecoverisinstalledwithoutgreasingthepumpshaft, the pumpsealcoulddamage.

• TherearetwoknockpinsAonthematingsurfacesof thecrankcaseandrightenginecover.
• Runthebreatherhose[B]intotheclamp[C]andposition itwiththerightenginecovermountingboltasshown.

Close-up mechanical assembly showing a central circular component with labeled parts A and B (no readable text or symbols)

Mechanical gear assembly showing interlocking gears and a central shaft (no text or symbols visible)

RightEngineCover

- WhenthereleaseleverAisturnedtotheright[B]lightly, choosetheamountofshims[C]ontheclutchpusher[D] sothattheincludedanglebetweenthereleaseleverA andtheline[E]attherightangletotherightenginecover isapprox.24°F.

• Stickthenewrightenginecovergasketinpositionwitha thinlayerofgrease.
• Applyahighttemperaturegreasekickshaftoilseallips andkickshaftspline.
• Torquetherightenginecoverboltsandkickshaftmountingbolt.

Torque-RightEngineCoverBolts:8.8N·m(0.90kgf·m,78in·lb)

KickPedalBolt:12N·m(1.2kgf ·m,89in·lb)

• Runtheclutchcableandthecoolinghosesaccordingto theCable, Wire, and HoseRoutingsectionintheGeneral Informationchapter.
• Adjusttheclutchcable(seethischapter).
• Checktheclutchreleaseleverangle.
• Fillthecrankcasewithengineoil(seeEngineBottom End/Transmissionchapter).
• Filltheenginewithcoolant(seeCoolingSystemchapter).

NOTICE

Donotremovetheclutchreleaseshaftunlessitis absolutelynecessary.Ifremoved,youmustreplace theoilsealwithanewone.

- Refertothecoolingsystemchapterforwaterpumpseal andwaterpumpbearingremoval.

RightEngineCover

RightEngineCoverDisassembly

• Removetherightenginecover(seethischapter).
• PullouttheclutchreleaseshaftA.

NOTICE

Donotremovetheclutchreleaseshaftunlessitis absolutelynecessary.Ifremoved,youmustreplace theoilsealwithanewones.

- Refertothecoolingsystemchapterforwaterpumpseal andwaterpumpbearingremoval.

Close-up of a mechanical component with a central shaft and circular features, labeled 'A' (no readable text or symbols beyond label)

RightEngineCoverAssembly

• Whentheoillevelgauge, needlebearingsandoilseal wereeremoved, notethefollowing.
  ○SetthenewoillevelgaugeAsothatitsmetalportion[B]facesoutwardandpressinthegaugeuntilitisbottomed.
  ○Pressthenewlowerneedlebearing[C]untilitisbottomed.Asfortheinstallationdirection,bothsidesare available.
  ○Setthenewupperneedlebearing[D]withthemarked sidefacingoutandpressbearinguntilitisbottomed.
  ○Pressthenewoilseals[E]untiltheyarebottomedand applyalittlehightemperaturegrease[F]ontherips.

• RefertotheCoolingSystemchapterforwaterpumpseal andwaterpumpbearinginstallation.

5-10ENGINERIGHTSIDE

Clutch

ClutchRemoval

• Removetherightenginecover(seeRightEngineCoverRemoval).

• RemovetheclutchpusherA, shimB and springplatepusher[C].

• Removethemagnetocover.

• Holdthemagnetoflywheelsteadywithflywheel&pulley holderA.

SpecialTool-Flywheel&PulleyHolder:57001-1605

- Remove:

ClutchHubNutA

ClutchSpringBolts[B]

ClutchSpringHolder[C]

ClutchHub[D]

- Remove:

FrictionPlatesandSteelPlates

ClutchWheel

ClutchHousing

SleeveandWashers

ClutchInstallation

• Applymolybdenumdisulfidegreasetotheoutsideofthe sleeveandclutchhousingbearinghole.
• Install:

ThrustWashersA

Sleeve[B]

ClutchHousing[C]

ClutchWheel[D]

FrictionPlatesandSteelPlates[E]

ClutchHub[F]

Mechanical assembly diagram showing a cam mechanism with labeled component A (no readable text or symbols)

Clutch

NOTICE

Ifdrysteelplatesandfrictionplatesareinstalled, applytransmissionoiltothesurfacesofeachplate toavoidclutchplateseizure.

○Installthefrictionplatesandsteelplates,startingwitha frictionplateandalternatingthem,finishingwithafriction plate.

○Installthehubnutandclutchspringbolts.

Torque-ClutchHubBolt:64N·m(6.5kgf·m,47ft·lb) ClutchSpringBolts:9.3N·m(0.95kgf·m,82in·lb)

• Applymolybdenumdisulfidegreasetotheclutchspring platepusher.
• Install: ClutchSpringPlatePusher Shim(asrequired) ClutchPusher MagnetoCover EngineRightSideCover

FrictionandSteelPlatesWear, DamageInspection

• Visually inspect the friction and steel plate to see if they show an sign of seizure, or uneven wear.
  ★Ifanyplatesshowsignsofdamage,replacethefriction platesandsteelplatesasaset.
• MeasurethethicknessAofthefrictionplates[B]and steelplateswithverniercalipers.
  ★Iftheyhavewornpasttheservicelimit,replace themwith newones.

FrictionPlateThickness

Standard: 3.1\~3.3mm

ServiceLimit: 2.9mm

SteelPlateThickness

Standard: 1.47\~1.73mm

ServiceLimit: 1.37mm

FrictionandSteelPlateWarpInspection

• Placeeachfrictionplateorsteelplateonasurfaceplate, andmeasurethegapbetweenthesurfaceplateAand eachfrictionplateorsteelplate[B]withathicknessgauge [C]Thegapistheamountoffrictionorsteelplatewarp.
  ★Ifanyplateiswarpedovertheservicelimit,replaceitwith anewone.

FrictionandSteelPlatesWarp

Standard:

FrictionPlateNotmorethan0.2mm

SteelPlate Not more than 0.15 mm

ServiceLimit:

FrictionPlate0.3mm

SteelPlate0.3mm

Clutch

SpringFreeLengthMeasurement

• SincethespringAbecomesshorterasitweakens, checkitsfreelengthtodetermineitscondition.
  ★ Ifanyofthespringsisshorterthantheservicelimit, it must bereplaced.

ClutchSpringFreeLength

Standard: 28.1mm

ServiceLimit: 26.7mm

FrictionPlate/ClutchHousingClearance Inspection

• Measure the clearance between the tongues A on the friction plate and the fingers [B] of the clutch housing.
  ★ If this clearance is excessive, the clutch will be noisy.
  ★ Iftheclearanceexceedstheservicelimit,replacethefrictionplates.

FrictionPlate/ClutchHousingClearance

Standard: 0.3\~0.6mm

ServiceLimit: 0.9mm

ClutchHubSplineInspection

• Visuallyinspectwheretheteethonthesteelplateswear againstthesplinesAofthe clutchhub.
  ★ Iftherearenotcheswornintothesplines,replace the clutchhub.Also,replacetheclutchplatesiftheirteeth aredamaged.

Technical line drawing of a mechanical gear assembly with labeled point A (no text or symbols beyond label)

ExternalShiftMechanism

ExternalShiftMechanismRemoval

- Remove:

ShiftPedal

RightEngineCover

ClutchHousing

- RemovetheenginemountingboltsAtopullouttheexternalshiftmechanism.

• PullouttheexternalshiftmechanismA, liftingtheengine [B].
• Removethegearsetleverspring[C].
• Removetheleversetscrew[D]andtakeoffthesetlevers [D][E].

ExternalShiftMechanismInstallation

• InstallthereturnspringAsothatthelargeroundedge sidefacesin.
• Beforeinstallingtheshiftshaft,applyhightemperature greasetotheoilseallipsandshiftshaftsplines.
• Tightenthegearsetleverscrew.

Torque-GearSetLeverScrew:8.8N·m(0.90kgf·m,78in·lb)

ShiftPedalBolt:8.8N·m(0.90kgf·m,78in·lb)

Close-up mechanical component with labeled point A, showing gears and shafts (no readable text or symbols)

ExternalShiftMechanismInspection

• ChecktheshiftshaftAforbendingordamagetothe splines.
  ★Iftheshaftisbent, straightenorreplaceit. Ifthesplines aredamaged, replacetheexternalshiftmechanism.
• Checkthereturnspring[B]andarmspring[C]forcracks ordistortion.
  ★ Ifthespringsaredamagedinanyway, replacethem.
• Checktheshiftmechanismarm[D]fordistortion.
  ★Iftheshiftmechanismarmisdamagedinanyway,re-placetheshiftmechanism.
• Checkthegearsetlevers, and it's spring for cracks or distortion.
  ★ Iftheleverorspringisdamagedinanyway, replacethem.

5-14ENGINERIGHTSIDE

PrimaryGear

PrimaryGearRemoval

• Removetherightenginecover(seeRightEngineCoverRemoval)
• RemovetheirclipA, and takeoff the primary gear[B] and waterpump drive gear.

SpecialTools-OutsideCirclipPliers:57001-144

PrimaryGearInstallation

- PutthewaterpumpdrivegearAandprimarygear[B]on thecrankshaft[C].Forthebothgears,installationeither obverseorreversesideisavailable.

Mechanical gear assembly diagram showing teeth and gears (no text or symbols)

PrimaryGearRemoval(KX65A6F \~)

• Removetherightenginecover(seeRightEngineCoverRemoval).
• Removethemagnetocover.
• RemovetheprimarygearnutA, washer, and the primary gear[B].
  ○Primarygearnutisleft-handthreads.

NOTE

○Usetheflywheel&p ulleyholdertopreventthecrank-shaftfromtherotating.

SpecialTools-Flywheel&PulleyHolder:57001-1605

PrimaryGearInstallation(KX65A6F \~)

• InserttheprimarygearAtothecrankshaftthenhollow sidefacingtotheoutside.
• Install: SpringWasher[B] PrimaryGearNut[C]

PrimaryGear

• InstallthespringwasherAwiththeconcavesidefacing totheinward.
• Temporarilytightentheprimarygearnut[B].

• Tightentheprimarygearnut
  ○Primarygearnutisleft-handthreads.

Torque-PrimaryGearNut:49N·m(5.0kgf·m,36ft·lb)

SpecialTools-Flywheel&PulleyHolder:57001-1605

NOTE

○ Usetheflywheel&pulleyholdertopreventthecrank-shaftfromtherotating.

- Install:

RightEngineCover(seeRightEngineCover)

MagnetoCover

5-16ENGINERIGHTSIDE

Kickstarter

KickshaftRemoval

• Remove:
  RightEngineCover(seeRightEngineCoverRemoval) ClutchHousing
• PulltheendofthekickspringAoutoftheholeinthe crankcase.
• Removetheratchetguidebolt[B]andratchetguidescrew [C],takeofftheratchetguide[D].
• Removethekickstarterassembly[E].

KickshaftInstallation

- Torquetheratchetguideboltandscrew. Torque-RatchetGuideBolts:8.8N·m(0.90kgf·m,78in·lb) RatchetGuideScrew:5.2N·m(0.53kgf·m,46 in·lb)

KickstarterAssemblyDisassembly/Assembly

- Thekickstarterassemblyconsistsofthefollowingparts. - Checkthekickstarterassemblypartsfordamage.Any damagedpartsshouldbereplacedwithne wones.

A.IdleGear
B.Circlip
C.Washer
D.Spring
E.RatchetGear
F.KickGear
G.KickShaft
H.KickSpring
I.SpringGuide

• Applymol ybdenumdisulfidegreasetotheinsideofthe kickgearandratchetgear.
• WhenassemblingtheratchetgearAontothekickshaft [B], a lignthenotch[C]ontheratchetgearwiththehole [D]onthekickshaft.
• Replacethecirclipsthatwereremovedwithnewones.

SpecialTool- OutsideCirclipPliers:57001-144

IdleGearRemoval

• Remove:
  RightEngineCover(seeRightEngineCoverRemoval) ClutchHousing(seeClutchRemoval)
• RemovethecirclipAandpullofftheidlegear[B].
  SpecialTool- OutsideCirclipPliers:57001-144

IdleGearInstallation

• Applymolybdenumdisulfidegreasetotheinsideofthe idlegear.
• Replacethecirclipwithanewone.
  SpecialTool- OutsideCirclipPliers:57001-144

Mechanical gear assembly with labeled components (A, B, C) and no visible text or symbols

EngineRemoval/Installation

TableofContents

Exploded View.... 6-2

Engine Removal/Installation 6-3

Engine Removal.... 6-3

Engine Installation.... 6-4

ExplodedView

1.Frame
2.PivotShaft
3.Swingarm

T1:25N·m(2.5kgf·m,18ft·lb)

29N·m(3.0kgf·m,21ft·lb):KX65-A3\~

T2:69N·m(7.0kgf·m,51ft·lb)

G:Applygrease.

L: Applyanon-permanentlockingagent.

GH020501W4 C

EngineRemoval/Installation

EngineRemoval

• Draintheengineoil(seeEngineBottomEnd/Transmissionchapter).
• Drainthecoolant(seeCoolingSystemchapter).
• Remove:

RadiatorShrouds

SideCovers

Seat

FuelTank

WaterHoses

Radiators

ExpansionChamber

SparkPlug

Carburetor(withCablesandHoses)

ClutchCableLowerEnd

DriveChain

EngineSprocket

ShiftPedal

BrakePedal

• Disconnectthemagnetooutputlead, andfreetheleads fromtheclamp.
• PlaceajackAundertheframetoliftthemotorcycleoff theground,andputblocksunderthefrontandreartires tosteadythemotorcycle.

WARNING

Sincetheswingarmpivotshaftalsoservesasthe enginemountingbolt,removingitmaycausethe motorcycletofalloverandcauseinjury.When removingtheswingarmpivotshaft,besurethe frameiswellsupportedsothemotorcyclewillnot fallwhenthepivotisremoved.

Mechanical assembly diagram showing labeled components A, B, and C (no text or symbols beyond labels)

SpecialTool-Jack:57001-1238

• Removetheenginemountingbolts[B].
• Pullouttheswingarmpivotshaft[C].
• Lifttheengineouttotheright.

EngineRemoval/Installation

EngineInstallation

• Installtheengineontheframe.
- Before tightening the engine mounting nuts, measure the left and right clearance A between the bosses [B] of crankcase and frame brackets [C] with thickness gauge.

Clearance: Under0.3mm

★ Iftheclearancesareoverthespecifiedvalue,adjustthem byinsertingtheshim(PartNo. 92180-1354)andtighten thefollowingnuts.

Torque-EngineMountingNuts:

25N·m(2.5kgf·m,18ft·lb) 29N·m(3.0kgf·m,21ft·lb):KX65-A3\~ SwingArmPivotShaftNut:69N·m(7.0kgf·m,51 ft·lb) Shift Pedal Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)

• Toroutetheleads, cablesandhoses, refertotheGeneral Informationchapter.
• Toinstallpartsremoved, refertotheappropriatechapters.
• Fillthecoolingsystemwithcoolant(seeCoolingSystem chapter).
• Filltheenginewithengineoil(seeEngineBottom End/Transmissionchapter).

- Adjust: ThrottleCable ClutchCable DriveCha in RearBrake

EngineBottomEnd/Transmission

TableofContents

Exploded View.... 7-2

Specifications 7-4

Transmission Oil 7-5

Oil Level Inspection.... 7-5

Oil Change 7-5

Crankcase 7-7

Crankcase Splitting 7-7

Crankcase Disassembly 7-8

Crankcase Assembly 7-8

Crankshaft, Connecting Rod 7-10

Crankshaft Removal 7-10

Crankshaft Installation 7-10

Crankshaft Disassembly 7-10

Crankshaft Assembly 7-10

Connecting Rod Big End Radial Clearance Inspection.... 7-11

Connecting Rod Big End Seizure Inspection 7-11

Connecting Rod Big End Side Clearance Inspection.... 7-11

Crankshaft Runout Inspection.... 7-11

Crankshaft Alignment Inspection 7-12

Transmission 7-13

Shaft Removal 7-13

Shaft Installation 7-13

Shaft Disassembly 7-13

Shaft Assembly 7-13

Shift Drum and Fork Installation.... 7-14

Shift Fork Bending Inspection 7-15

ShiftFork/GearGrooveWearInspection....7-15

ShiftForkGuidePin/ShiftDrumGrooveWearInspection....7-15

Gear Damage Inspection.... 7-16

GearDog/GearDogHoleDamageInspection....7-16

Ball Bearing Wear Inspection.... 7-16

7-2 ENGINEBOTTOMEND/TRANSMISSION

ExplodedView

ExplodedView

1. CrankshaftAssembly
   2.MagnetoStator
   3.MagnetoFlywheel
   4.LeftCrankcase
   5.RightCrankcase
   6.DriveShaft
2. OutputShaft
3. EngineSprocket
   9.ShiftRod
   10.ShiftFork
4. OperatingPlate
   12.ShiftDrum
   13.ShiftShaft
   14.ShiftPedal
   15.KX65-A1\~A5
   16.KX65-A1\~A6
   T1:20N·m(2.0kgf·m,15ft·lb)
   T2:29N·m(3.0kgf·m,21ft·lb)
   T3:8.8N·m(0.90kgf·m,78in·lb)
   T4:8.8N·m(0.90kgf·m,78in·lb)
   T5:24N·m(2.4kgf·m,17ft·lb)
   T6:8.8N·m(0.90kgf·m,78in·lb)
   T7:5.2N·m(0.53kgf·m,46in·lb)
   EO:Applyengineoiltothetransmissiongearsandshiftforks,etc.
   G: Apply hightemperaturegrease.
   L: Applyanon-permanentlockingagent.
   LG:Applyliquidgaskettotheleftandrightcasematingsurface.
   M:Applymolybdenumdisulfidegrease.
   O:Apply2-strokeengineoil.
   R: Replacementparts

Specifications

Item	StandardServiceLimit
TransmissionOil:EngineOil:GradeViscositySAE10W-40-- Capacity0.5L--	APISG,SH,SJ,SLorSMwithJASOMA,MA1orMA2	---
Crankshaft,ConnectingRodConnectingRodBendNotmorethan0.05mm/100mm0.2mm/100mmConnectingRodTwistNotmorethan0.05mm/100mm0.2mm/100mmConnectingRodBigEndRadial ClearanceConnectingRodBigEndSide ClearanceCrankshaftRunout	0.025~ 0.037mm0.09mm0.35~ 0.45mm0.65mmNotmorethan0.03mm	0.05mm
TransmissionShift Fork Ear ThicknessGear Shift Fork Groove WidthShift Fork Guide Pin DiameterShiftDrumGrooveWidth	3.90 ~ 4.00 mm4.05 ~ 4.15 mm5.90 ~ 6.00 mm6.05~ 6.20mm6.25mm	3.80 mm4.25 mm5.80 mm

Special Tools - Bearing Puller Adapter: 57001-136

OutsideCirclipPliers: 57001-144

BearingPuller: 57001-158

BearingDriverSet:57001-1129

CrankcaseSplittingToolAssembly:57001-1362

CrankshaftJig: 57001-1439

Sealant - LiquidGasket, TB1105B:92104-002

TransmissionOil

Inorderforthetransmissionandclutchtofunctionproperly,alwaysmaintainthetransmissionoilattheproperlevel andchangetheoilperiodically.

WARNING

Vehicleoperationwithinsufficient,deteriorated,or contaminatedtransmissionoilwillcauseacceleratedwearandmayresultinengineortransmission seizure,accident,andinjury.Checktheoillevelbeforeeachuseandchangetheoilandfilteraccordingtotheperiodicmaintenancechart.

OilLevelInspection

• Situatethemotorcyclesothatitisperpendiculartothe ground.
• Ifthemotorcyclehasjustbeenused, waitseveralminutes untiltheoilsettles.
• Checkthattheoillevelcomesupbetweentheupperlevel Aandlowerlevel[B]throughtheoillevelgauge[C]ontherightenginecover.
  ★ If the oil level to high, removal the excess oil through the oil filler opening using asyringe or some others suitable device.
  ★Iftheoillevelistoolow,addthecorrectamountofoil. Usethesametypeandmakeofoilthatisalreadyinthe engine.

NOTE

○ Iftheengineoiltypeandmakeareunknown,useany brandofthespecifiedoiltotopupthelevelinpreference torunningtheenginewiththeoillevellow. Thenatyour earliestconvenience,changetheoilcompletely.

OilChange

• Warmuptheenginethoroughlysothattheoilwillpickup anysedimentanddraineasily. Thenstoptheengine.
• Placeanoilpanbeneaththeengine
• RemovetheengineoidrainplugAonthebottomofthe engine, andlettheoidraincompletely.

NOTE

○ Holdthemotorcycleuprightsothattheoilmaydrain completely.

TransmissionOil

• Checkthegasketattheengineoildrainplugfordamage.
  ★Replacethegasketwithanewoneifitisdamaged.
• Aftertheoilhascompletelydrainedout,installtheengine oildrainplugwiththegasket,andtightenit.

Torque-EngineOilDrainPlug:20N·m(2.0kgf·m,15ft·lb)

• Filltheenginewithagoodqualityengineoilspecifiedbelow.
• Checktheoillevel.

RecommendedEngineOil

Grade: APISG, SH, SJ, SL or SM with JASOMA, MA1 or MA2

Viscosity: SAE10W-40

EngineOilCapacity

Capacity: 0.5L

NOTE

○Donotaddanychemicaladditivetotheoil. Oilsfulfilling theaboverequirementsarefullyformulatedandprovide adequatelylubricationforboththeengineandtheclutch.

Although 10W-40engineoilistherecommendedoilfor most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.

Crankcase

CrankcaseSplitting

• Removetheengine(seetheEngineRemoval/Installation chapter).
• Settheengineonacleansurfacewhilepartsarebeing removed.
• Remove:

MagnetoCover

OutputShaftSleeveAandO-ring[B]

CylinderHead(seeEngineTopEndChapter)

Cylinder(seeEngineTopEndChapter)

Piston(seeEngineTopEndChapter)

RightEngineCover(seeEngineRightSideChapter)

Clutch(seeEngineRightSideChapter)

PrimaryGear(seeEngineRightSideChapter)

KickstarterAssembly(seeEngineRightSideChapter)

KickstarterIdleGear(seeEngineRightSideChapter)

GearSetandNeutralSetLeversA

MagnetoFlywheelandStator(seeElectricalSystem

Chapter)

- RemovethecrankcaseboltsA.

Close-up of a mechanical component with labeled parts (A), showing internal gears and mounting holes (no readable text or symbols)

- InstallthecrankcasesplittingtoolAandadapter[B]into theleftsideofthecrankcase.Becertaintoscrewthetool inalltheway.

SpecialTools-CrankcaseSplittingToolAssembly:57001-1362

BearingPullerAdapter:57001-136

• Tightentheboltonthecrankcasesplittingtooltosplitthe crankcasehalves.
• Oncethecrankcaseissplit,removethecrankcasesplittingtool,andliftofftheleftcrankcasehalf.

Crankcase

• PullouttheshiftrodsA.
• Disengagetheshiftforkguidepinsfromtheshiftdrum grooves.
• Takeofftheshiftdrum[B]
• Removetheshiftforks[C]fromthetransmissiongears.
• Takeoutthedriveshaft[D]andoutputshaft[E]together withtheirgearmeshed.
• Removethecrankshaftfromtherightcrankcasehalfusingapress.

CrankcaseDisassembly

NOTICE

Donotremovethebearingsandtheoilsealsunless itisnecessary. Removalmaydamagethem.

CrankcaseAssembly

• Beforefittingtheleftcaseontherightcase,notethefollowing:
  ○ Chipofftheoldgasketfromthematingsurfacesofthe crankcasehalves, andcleanoffthecrankcasewithahigh flash-pointsolvent. Aftercleaning, applytransmissionoil tothetransmissiongears, shiftdrum, shiftforksandso on.
  Besuretoreplaceanyoilsealremovedwithanewone. Pressinthenewoilsealusingapressandsuitabletools sothatthesealsurfaceisflushwiththesurfaceofthe crankcase.

○AsforthecrankshaftoilsealA,ontherightcrankcase half[B]pressinthesealuntilitisbottomed.
○Applyhightemperaturegreasetotheoilseallips.
○Pressintheballbearingsusingthebearingdriversetuntil thebearingisbottomed.

SpecialTool-BearingDriverSet:57001-1129

○ Tightenthedriveshaftbearingretainingscrewssecurely. Torque-BearingRetainingScrews:8.8N·m(0.90kgf·m,78 in·lb)

○ Ifthecrankshaftbearingsstayonthecrankshaftwhen splittingthecrankcase,removethebearingsfromthe crankshaftandreinstalltheminthecrankcase,andthen assemblethecrankcase(seeCrankshaftRemovaland Installation).

Crankcase

- TurnthecrankshaftAtoBDC[B], and install the crankshaft jig[C] between the fly wheels opposite the connecting rodbig end to protect fly wheel alignment as shown. Install the suitable shaft[D] to there are end of the crankshaft jig.

Ofthecrankshafthasbeenremovedfromthecrankcase, installthejigbetweenthecrankshaftflywheelsbefore pressingthecrankshaftintotherightcrankcasehalf.

SpecialTool-CrankshaftJig:57001-1439

• Installthetransmissionshaftasaset(seethischapter).
- Installtheshiftfork, shiftdrumandshiftrod.
- Checktoseethatthecrankcaseknockpinsareinplace ontherightcrankcasehalf.Ifanyofthemhasbeenremoved,replaceitwithanewone.
- ApplyliquidgaskettothematingsurfaceAoftheleft crankcasehalf.

Sealant-LiquidGasket, TB1105B:92104-002

- UsingasuitabletoolontheleftcrankcasetopressA aroundtheholeforthecrankshaft,fitthecrankcase halvestogetherwithapressonthetool.

NOTE

○ Constantlycheckthealignmentofthetwocrankcase halves, and the positionofthetransmissionshafts, and shiftdrum. Thefrontandrearofthecrankcasemustbe pushedtogetherevenly.

Mechanical assembly diagram showing internal components and a labeled section A (no readable text or symbols)

• Removethecrankshaftjigfromtheflywheels.
• Tightenthecrankcaseboltsstartingwiththeonesaround thecrankshaft,andthenthefartherones.

Torque - Crankcase Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)

• Checktoseethatthecrankshaft,driveshaft,andoutput shaftallturnfreely(intheneutralposition).
  ★ Ifthecrankshaftwillnotturn, probablythecrankshaft is not centered; taptheappropriateendofthecrankshaft withamallettorepositionit.
• Spinningtheoutputshaft, shiftthetransmissionthrough allthegearstomakecertainthereisnobindingandthat allthegearsshiftproperly.
• Installthepartsremovedinthereverseorderofremoval, andrefertotheappropriatechapters.

○ReplacetheO-ringontheoutputshaftwithanewone.

7-10 ENGINEBOTTOMEND/TRANSMISSION

Crankshaft, ConnectingRod

CrankshaftRemoval

• Splitthecrankcase(seeCrankcaseSplitting).
• Removethetransmissionshafts(seeTransmissionShaftRemoval).
• Usingapress,removethecrankshaftfromtheright crankcase.
  ○ Ifthebearingsstayonthecrankshaftwhensplittingthe crankcaseorremovingthecrankshaftfromtheright crankcase,removethebearingsfromthecrankshaftwith abearingpullerAandadapter[B].

SpecialTools-BearingPuller:57001-158

BearingPullerAdapter:57001-136

CrankshaftInstallation

• Wheninstallingthecrankshaftbearings[B],applyhigh temperaturegreasetotheoutersidesofthebearings, andthenpressthemintothecrankcaseusingthebearing driverAuntilthebearingbottomsagainstthestep.
  ○ Positionthecrankcasehalfsothatthemainbearinghousingisseatedonasuitablepressfixture.
  ○ Installthecrankshaftbearingsothatthesealedsidein(to theoilseal[C]side).

SpecialTool-BearingDriverSet:57001-1129

• InsertthecrankshaftjigAbetweenthecrankshaftfly-wheels opposite the connecting rod big end to protect flywheelalignmentasshown, and using asuitabletool [B]ontheleftcrankcasetopressaroundtheholeforthe crankshaft.
  When pressing, position the jig in the crank case opening so the jig does no that the crank case.

SpecialTool-CrankshaftJig:57001-1439

- Apply2-strokeoiltotheconnectingrodbigendbearing.

CrankshaftDisassembly

Sinceassemblyofthecrankshaftdemandsexactingtolerances, thedisassemblyandreassemblyofthecrankshaft canonlybedonebyashophavingthenecessarytoolsand equipment.

- Ifitshouldbenecessarytodisassemblethecrankshaft, useapresstoremovethecrankpin.

CrankshaftAssembly

Sincetheassemblyofthecrankshaftdemandsexacting tolerances, thedisassemblyandreassemblyofthecrankshaftcanonlybedonebyashophavingthenecessarytools andequipment.

• ReassemblethecrankshaftaccordingtothestandardtolerancesinSpecifications.
  ○Connectingrodbend,twist
  ○Connectingrodbigendradialclearance.
  ○ Cold-fittingtolerancebetweenencrankpinandflywheels.
  ○Sideclearancebetweentheconnectingrodbigendand oneofflywheels.
  ○ Crankshaftrunout.

Crankshaft, ConnectingRod

ConnectingRodBigEndRadialClearance Inspection

• SetthecrankshaftinaflywheelalignmentjigoronV blocks, and placeadialgaugeagainsttheconnectingrod bigend.
• Pushtheconnectingrodfirsttowardsthegaugeandthen intheoppositedirection. Thedifferencebetweenthetwo gaugereadingsisteradialclearance.
  ★Iftheradialclearanceexceedstheservicelimit,thecrankshaftshouldbeeitherreplacedordisassembledandthe crankpin,needlebearing,andconnectingrodbigendexaminedforwear.

ConnectingRodBigEndRadialClearance

Standard: 0.025\~0.037mm

ServiceLimit: 0.09mm

Pure mechanical diagram showing a pulley system with no text or symbols

ConnectingRodBigEndSeizureInspection

★Incaseofseriousseizurewithdamagedflywheels,the crankshaftmustbereplaced.
★Incaseoflessseriousdamage,disassemblethecrankshaftandreplacethecrankpin,needlebearing,side washers,andconnectingrod.

ConnectingRodBigEndSideClearance Inspection

• MeasurethesideclearanceAoftheconnectingrodwith athicknessgauge.
  ★Iftheclearanceexceedstheservicelimit,replace the crankshaft.

ConnectingRodBigEndSideClearance

Standard: 0.35\~0.45mm

ServiceLimit: 0.65mm

CrankshaftRunoutInspection

• SetthecrankshaftinaflywheelalignmentjigoronV blocks, and placeadialgaugeagainststhepointsindicated.
• Turnthecrankshaftslowly. Themaximumdifferencein gaugereadingsisthecrankshaftrunout.
  ★ Iftherunoutateitherpointexceedstheservicelimit, align theflywheelssothattherunoutfallswithintheservice limit.

CrankshaftRunout

Standard: Not more than 0.03 mm

ServiceLimit: 0.05mm

7-12 ENGINEBOTTOMEND/TRANSMISSION

Crankshaft, ConnectingRod

CrankshaftAlignmentInspection

• In the case of horizontal misalignment, which is most common, strikethe projecting grimof the flywheel with a plastic, softlead, or brasshammer as indicated in the figure.
• Rechecktherunoutwithadialgauge,repeatingthe processuntiltherunoutfallswithintheservicelimit.
  ○ Verticalmisalignment is corrected either by driving a wedge in between the fly wheels or by squeezing the fly wheel rims in advance, depending on then nature of the misalignment. In cases of both horizontal and vertical misalignment, correct the horizontal misalignment first.

Technical illustration of a mechanical assembly showing two views of a cylindrical component with threaded ends and a shaft (no text or symbols)

NOTICE

Don'thammertheflywheelatpoint"A".

★ Ifflywheelmisalignmentcannotbecorrectedbytheabove method,replacecrankpinorthecrankshaftitself.

graph TD
    A["Step 1: Initial mechanical component"] --> B["Step 2: Rotation of a mechanical part"]
    B --> C["Step 3: Pulling mechanism"]
    C --> D["Step 4: Final assembly with labeled component 'A'"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333

Transmission

ShaftRemoval

• Splitthecrankcase(seeCrankcaseSplitting).
• PullofftheshiftrodsA, and disengagetheshiftfork guidepinsfromtheshiftdrumgrooves.
• Removetheshiftdrum[B]
• Removetheshiftforks[C]fromthetransmissiongears.
• Takeoutthedriveshaft[D]andoutputshaft[E]together, withtheirgearsmeshed.

ShaftInstallation

• HoldthedriveshaftAandoutputshaft[B]together,with theirgearsmeshed,andfitthemintotherightcrankcase half.
• Toinstalltheshiftforksandshiftdrum,seetheShiftDrum andForkInstallation.

Mechanical gear assembly with labeled components A and B (no text or symbols beyond labels)

ShaftDisassembly

• Removethetransmissionshafts(seeShaftRemoval).
• Usingcirclipplierstoremovethecirclips,disassemblethe transmissionshaft.

SpecialTool-OutsideCirclipPliers:57001-144

ShaftAssembly

• Applytransmissionoilliberallytothetransmissionshaft, gearsandbe arings.
• Replaceanycirclipsthatwereremovedwithnewones. ○AlwaysinstallcirclipsAsothattheopening[B]isaligned withasplinegroove[C].

SpecialTool-OutsideCirclipPliers:57001-144

- Thedriveshaftgearscanbeidentifiedbysize;thesmall-estdiametergearis1stgear,andthelargestis6th.Be surethatallpartsareputbackinthecorrectsequence, andfacingtheproperdirection,andthatallcirclipsand thewashersareproperlyinplace.

A1stGear(13T;partofdriveshaft)
[B]6thGear(24T; plainsidefacesright)
[C]3rd/4thGear(18T/21T;largergearfacesleft)
[D]5thGear(23T; plainsidefacesleft)
[E]2ndGear(16T;eithersidemayfacein)
[F]Circlip(1.2×15×19)

Transmission

- The output shaft gears can be identified by size; the largest diameter gear is 1st gear, and the smallest is 6th. Besure that all parts are put back in the correct sequence and facing the proper direction, and that all circlips are properly in place.

A2ndGear(34T; dogrecessesfaceright)
[B]5thGear(28T;forkgroovegoestotherightsideof thegearteeth)
[C]4thgear(30T; dogrecessesfaceleft)
[D]3rdgear(31T; dogrecessesfaceright)
[E]6thgear(26T;forkgroovegoestotheleftsideofthe gearteeth)
[F]1stgear(37T; plainsidefacesright)
[G]Circlip(1.2×18)
[H]Circlip(1.2×18×23.5)

- Check that each gear spins or slides freely on the transmission shaft without binding after assembly.

ShiftDrumandForkInstallation

- Applyalittletransmissionoiltotheshiftforkears, and fit theshiftforksintothegeargrooves.

ShiftForkIdentification

Driveshaft3rdgearand4th gearshiftfork[A]	earsareshorterthanthoseof theothertwoshiftforks
Outputshaft5thand6thgear shiftforks[B]	earsarelonge rthanthedrive shaft3rd/4rd gearshiftfork

Two metallic mechanical components labeled A and B, shown side by side (no text or symbols on the parts themselves)

Transmission

• Installtheshiftdrum.
- Fittheshiftforkguidepinsintothecorrespondingshift drumgrooves.
- Applyalittletransmissionoiltotheshiftrods, and slide themintotheshiftforks.
- Holdingtheshiftdrumwiththesuitabletoolandtighten theshiftdrumoperatingplatebolt.
○Applyanon-permanentlockingagenttotheshiftdrum operatingplatebolt.

Torque-ShiftDrumOperatingPlateBolt:24N·m(2.4 kgf·m,17ft·lb)

ShiftForkBendingInspection

- Visuallyinspecttheshiftforks, and replaceanyforkthatis bent. Abentforkcouldcausedifficultyinshifting, orallow thetransmissiontojumpoutofgearwhenunderpower. A90°

ShiftFork/GearGrooveWearInspection

- MeasurethethicknessoftheshiftforkearsA, and measurethewidth[B]oftheshiftforkgroovesinthetransmissiongears.

★ Ifthethicknessofashiftforkearislessthantheservice limit, theshiftforkmustbereplaced.

ShiftForkEarThickness

Standard: 3.90\~4.00mm

ServiceLimit: 3.80mm

★Ifagearshiftforkgrooveiswornovertheservicelimit, thegearmustbereplaced.

ShiftF orkGrooveWidth

Standard:4.05\~4.15mm

ServiceLimit:4.25mm

ShiftForkGuidePin/ShiftDrumGrooveWear Inspection

• MeasurethediameterAofeachshiftforkguidepin,and measurethewidth[B]ofeachshiftdrumgroove.
  ★ Iftheguidepinonanyshiftforkislessthantheservice limit, theforkmustbereplaced.

ShiftForkGuidePinDiameter

Standard: 5.90\~6.00mm

ServiceLimit: 5.80mm

★Ifanyshiftdrumgrooveiswornovertheservicelimit,the drummustbereplaced.

ShiftDrumGrooveWidth

Standard: 6.05\~6.20mm

ServiceLimit: 6.25mm

Transmission

GearDamageInspection

• Visuallyinspectthegearteethonthetransmissiongears.
  ★Repairlightlydamagedgearteeethwithanoilstone. The gearmustbereplacediftheteetharebadlydamaged.
  ★ Whengearisrepairedorreplaced, thedrivinggearshould also be inspected and repaired or replaced if necessary.

GearDog/GearDogHoleDamageInspection

• VisuallyinspectthegeardogsAandgeardogholes[B].
  ★Replaceanydamagedgearsorgearswithexcessively worndogsordogholes.

Technical illustration of two gear assemblies labeled A and B, showing internal components and alignment lines (no text or symbols beyond labels)

BallBearingWearInspection

• Checktheballbearingonthecrankcase.
  ★ Sincetheballbearingsaremadetoextremelyclosetolerances, thewearmustbejudgedbyfeelratherthanmeasurement. Cleaneachbearinginahighflash-pointsolvent, dryit(donotspinthebearingwhileitisdry), andoil itwithtransmissionoil.
  ○ Spinthebearingbyhandtocheckitscondition.
  ★ Ifthebearingisnoisy, does not spinsmoothly, or has any roughspots, replace it.

Wheels/Tires

TableofContents

Exploded View 8-2

Specifications 8-3

Wheels (Rims) 8-4

Front Wheel Removal 8-4

Front Wheel Installation 8-4

Rear Wheel Removal 8-5

Rear Wheel Installation 8-6

Wheels Inspection.... 8-7

Spoke Inspection 8-7

Rim Inspection 8-8

Axle Inspection.... 8-8

Tires 8-9

AirPressureInspection/Adjustment....8-9

Tires Inspection 8-9

Tire Removal 8-10

Tire Installation.... 8-11

Hub Bearings.... 8-12

Hub Bearing Removal 8-12

Hub Bearing Installation 8-12

Bearing Inspection 8-13

ExplodedView

1.Nipple
2.Spoke
3.FrontTire
4.Rim
5.FrontAxle
6.Swingarm
7.RearTire
8.RearAxle

T1:1.5N·m(0.15kgf·m,13in·lb)

• UsingthejackAundertheframe, and stabilizethemotorcycle.
  SpecialTool-Jack:57001-1238
• Placeastandundertheenginetoraisethefrontwheel theground.

- RemovethecotterpinA

- Unscrewtheaxlenut[B].

- RemovetheaxleA, and pulloutthewheel. Takeoff the collar[B] and cap[C] from each side of the fronthub.

NOTICE

Donotlaythewheelonthegroundwiththedisc facingdown. This candamageorwarpthedisc. Placeblocksunderthewheelsothediscdoesnot touchtheground.

- Insertawoodwedgebetweenthediscbrakepads. This preventsthemfrombeingmovedoutoftheirproperposition,shouldthebrakeleverbesqueezedaccidentally.

FrontWheelInstallation

• ApplygreaseAtotheseals.
• Fittheprojectiononthecaptothegrooveonthecollar.
• Installthecaps[B]collars[C]ontheleftandrightsideof thehub. Thecollarsandcapsarethesame.
• Inserttheaxle[D]fromleftside.
• Tightenthefrontaxlenut[E].

Mechanical assembly diagram showing a vehicle with labeled component A (no readable text or symbols)

Wheels(Rims)

- InsertanewcotterpinA.

NOTE

○ Wheninsertingthecotterpin,iftheslotsinthenutdo notalignwiththecotterpinholeintheaxle,tightenthe nutclockwise[B]uptonextalignment.
○ Itshouldbewithin30degree.
○ Loosenonceandtightenagainwhentheslotgoespast thenaresthole.

- BendthecotterpinAoverthenut[B].

• Removethejack.
• Checkthefrontbrakeforgoodbrakingpowerandno brakedrag.

WARNING

Afterservicing, ittakesseveral applications of the brakelever before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Donot attempt toridethemotor cycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc.

RearWheelRemoval

- Usingthej ackundertheframesothattherearwheelis raisedofftheground.

SpecialTool-Jack:57001-1238

- RemovetheclipAfromthemasterlinkusingpliers,and freethedrivechain[B]fromtherearsprocket.

Wheels(Rims)

• RemovethecotterpinA.
• Removetheaxlenut[B].
• Pullouttheaxle[C].
• Movetherearwheelbackwiththerearcaliperinstalled.
• Takeoffthecollarandcapfromtheeachsideoftherear hub.

NOTICE

Donotlaythewheelonthegroundwiththedisc facingdown. This candamageorwarpthedisc. Placeblocksunderthewheelsothediscdoesnot touchtheground.

- Insertawoodwedgebetweenthebrakepads. This preventsthemfrombeingmovedoutoftheirproperposition, shouldthebrakepedalbesqueezedaccidentally.

RearWheelInstallation

- FitthebrakeholderstopAagainstthestopprojection [B]ontheswingarm.

• ApplygreaseAtotheseals.
• Fittheprojectiononthecaptothegrooveonthecollar.
• Installthecaps[B]andcollars[C]ontheleft(longercollar) andright(shortercollar)sideofthehub.
• Installthedrivechain.InstalltheclipAsothattheclosed endofthe"U"[B]pointsinthedirectionofchainrotation [C].
• Checkthedrivechainslack(seeFinalDrivechapter).
• Inserttheaxlefromleftsideandtightentherearaxlenut.

Torque - Rear Axle Nut: 79 N·m (8.0 kgf·m, 58 ft·lb)

Wheels(Rims)

- InsertanewcotterpinA.

NOTE

○ Wheninsertingthecotterpin,iftheslotsinthenutdo notalignwiththecotterpinholeintheaxle,tightenthe nutclockwise[B]uptonextalignment.
○ Itshouldbewithin30degree.
○ Loosenonceandtightenagainwhentheslotgoespast thenaresthole.

- BendthecotterpinAoverthenut[B].

- Checktherearbrakeforgoodbrakingpowerandno brakedrag.

WARNING

Afterservicing, ittakesseveral applications of the brakepedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Donot attempt toridethemotor cycle until a firm brake pad is obtained by pumping the pedal until the pads are against the disc.

WheelsInspection

- Placethejackundertheframesothatthefront/rearwheel israisedo fftheground.

SpecialTool-Jack:57001-1238

• Spinthewheellightly, and check for roughnessor binding.
  ★lfro ughnessorbindingisfound,replacethehubbearings.
• Visuallyinspectthefrontandrearaxlesfordamage.
  ★ Ifaxleisdamagedorbent, replaceit.

Spokelnspection

• Checkthatallthespokesaretightenedevenly.
  ★Ifspoketightnessisunevenorloose,tightenthespoke nipplesevenly.

Torque-SpokeNipples:1.5N·m(0.15kgf·m,13in·lb)

- Checktherimrunout.

WARNING

Amissingspokeplacesanadditionalloadon theotherspokes,whichwilleventuallycause otherspokestobreak,creatingthepotentialfor anaccidentresultinginseriousinjuryor death. Immediatelyreplaceanybrokenspoke(s).

Wheels(Rims)

RimInspection

• Removethewheel, and support it with the tire by the axle.
• Measuretherimrunout, axialA and radial[B], with radial gauge.
  ★ Iftherimrunoutexceedstheservicelimit, checkthehub bearings. Replacethemiftheyaredamaged.
  ★ If the problem is not due to the bearings, correct therim warp (runout). Acertain amount of trim warpcan be corrected by recentering therim. Loosensomespokes and tighten part of therim. If therim is badly bent, however, it must bere placed.

RimRunout(withtireinstalled)

Standard:

AxialTIR1.0mmorless

RadialTIR1.0mmorless

ServiceLimit:

AxialTIR2mm

RadialTIR2mm

AxleInspection

• Visuallyinspectthefrontandrearaxlefordamages.
  ★ Iftheaxleisdamagedorbent,replaceit.
• PlacetheaxleinVblocksthatare100mmAapart, and setadialgaugeontheaxleatapointhalfwaybetween theblocks. Turntheaxletomeasuretherunout. The differencebetween the highest and lowest dialreadings is the amount of runout.
  ★ Ifrunoutexceedstheservicelimit, replacetheaxle.

AxleRunout/100mm

Standard: Under0.1mm

ServiceLimit: 0.2mm

Tires

AirPressureInspection/Adjustment

• UsingtireairpressuregaugeA,measurethetirepressurewhenthetiresarecold.
  ★Adjustthetireairpressuretosuittrackconditionsand riderpreference, butdonotstraytoofarfromtherecommendedpressure.

TrackCondition	TirePressure
Whenthetrackiswet,muddy,sandy orslippery,reducethetirepressureto increasethetiretreadsurfaceonthe ground.	80kPa(0.8kgf/cm2,11psi)↑
Whenthetrackispebblyorhard, increasethetirepressuretoprevent damageorpunctures,throughthe tireswillskidmoreeasily.	↓98kPa(1.0kgf/cm2,14psi)

TiresInspection

Asthetiretreadwearsdown, thetirebecomesmoresusceptiblethepunctureandfailure.

• Removeanyimbeddedstonesorotherforeignparticles fromthetread.
• Visually inspect the tire for cracks and cuts, replacing the tire in case of baddamage. Swelling or high spots indicate internal damage, requiring tirereplacement.

WARNING

Somereplacementtiresmayadverselyaffecthandlingandcauseanaccidentresultinginserious injuryordeath.Toensureproperhandlingandstability,useonlytherecommendedstandardtiresfor replacement,inflatedtothestandardpressure.

Technical line drawing of a tire track with suspension components (no text or symbols)

NOTE

○ Checkandbalancethewheelwhenatireisreplaced withanewone.

StandardTire

Front:

Size:60/100-1430M

Make: DUNLOP

Type: D755F, Tube(KX65-A1\~A6)

D756F, Tube

Rear:

Size:80/100-1241M

Make: DUNLOP

Type: D755, Tube(KX65-A1\~A6)

D756, Tube

Tires

TireRemoval

NOTICE

Donotlaythewheelonthegroundwiththedisc facingdown. This candamageorwarpthedisc. Placeblocksunderthewheelsothediscdoes not touchtheground.

• Removethewheelfromthemotorcycle(seeWheelsRemoval).
• Tomaintainwheelbalance, markAthevalvestempositiononthetirewithchalksothatthetirecanbereinstalled inthesameposition.
  • Takeoutthevalvecore[B]toletouttheair.
• Removethevalvestemnut[C].
  ○Whenhandlingtherim, be careful not to damage therim flanges.
• Removethebeadprotectornut.
• Lubricatethetirebeadsandrimflangesonbothsideswith asoapandwatersolutionorrubberlubricant. Thishelps thetirebeadsslipofftherimflanges.

NOTICE

Neverlubricatewithmineraloil(engineoil)orgasolinebecausetheywillcausedeteriorationofthetire.

• Breakthebeadsawayfrombothsidesoftherimwiththe beadbreakerA.
  SpecialTool-BeadBreakerAssembly:57001-1072

• Steponthesideofthetireoppositevalvestem, prythe tireofftherimwiththetireironAofthebeadbreaker protectingtheri mwithrimprotectors[B].
  SpecialTools-RimProtector:57001-1063
  TireIronProtectionoftheBeadBreakerAs-sembly:57001-1072

NOTICE

Takecarenottoi nsertthetireironssodeeplythat thetubegetsdamaged.

• Removethetubewhenonesideofthetireispriedoff.
• Prythetireofftherim.

Tires

TireInstallation

• Inspecttherimandtire, and replacethemifnecessary.
• Installthetube.
• Applyasoapandwatersolution,orrubberlubricanttotherimflangeandtirebeads.
• PositionthetireontherimsothatthevalveAisatthetire balancemarkB.
• Insertthevalvestemintotherim, andscrewthenuton loosely.
• Fittherimprotectorsandusetireironstoinstallthetire bead.

NOTE

○ Topreventrimdamage, besuretoplacetherimprotectorsatanyplacethetireironsareapplied.

• Pryonesideofthetirebackontotherim.Fitthebead protectorintothetire.
• Prytheothersideofthetireontotherim, startingatthe sideoppositethevalve.
  ○Takecarenottoinsertthetireironssodeeplythatthe tubeisdamaged.
• Installtheothersideofthetirebeadontotheriminthe samemanner.
• Check that the tube is not pinched between the tire and rim.
• Tightenthebeadprotectornutandvalvestemnut,and putonthevalvecap.
• Checkandadjusttheairpressureafterinstalling.

HubBearings

HubBearingRemoval

- Removethewheel(seeWheelRemoval).

NOTICE

Donotlaythewheelonthegroundwiththedisc facingdown. Thiscandamageorwarpthedisc. Placeblocksunderthewheelsothatthediscdoes nottouchtheground.

• Removetheoilsealsandcirclip.
• Removethehubbearingbytappingevenlyaroundthe bearinginnerraceasshown.
  ABar
  [B]DistanceCollar
  [C]HubBearing

HubBearingInstallation

• Beforeinstallingthewheelbearings,blowanydirtorforeignparticlesoutofthehubwithcompressedairtopreventcontaminationofthebearings.
• InstallthebearingsAbyusingthebearingdriverset[B] whichdoesnotcontactthebearinginnerrace.
  SpecialTool-BearingDriverSet:57001-1129

NOTE

○Installthebearingssothatthemarkedside,orthe sealedsidefacesout.

○Pressinthebearingsasfollows.
○WhenthebearingsareinstalledinthefronthubA,press intherightsidebearing[B]untilitisbottomedagainstthe step[C]ofthehub.Andpressinth eleftsidebearing[D] untilitisbottomedagainstthecollar[E].

○WhenthebearingsareinstalledintherearhubA,press intheleft sidebearing[B]untilitisbottomedagainststhe step[C]ofthehub.Andpressintherightsidebearing[D] untilitisbottomedagainststhecollar[E].

HubBearings

• Replacethecirclipandoilsealswithnewones.
• PressintheoilsealsAsothatthesealsurfaceisflush [B]withtheendofthehole.
• Applyhightemperaturegreasetotheoilseallips.

SpecialTool-BearingDriverset:57001-1129[C]

InsideCirclipPliers:57001-143

BearingInspection

NOTE

- Itisnotnecessarytoremoveanybearingsforinspection.Ifanybearingsareremoved,theywillneedtobe replacedwithnewones.

• SpinAitbyhandtocheckitscondition.
  ★ Ifitisnoisy, does not spins smoothly, or has any rough spots, it must bere placed.
• Examinethebearingseal[B]fortearsorleakage.
  ★Ifthesealistornorisleaking,replacehebearing.

FinalDrive

TableofContents

Exploded View 9-2

Specifications 9-3

Drive Chain.... 9-4

Drive Chain Slack Inspection.... 9-4

Drive Chain Slack Adjustment 9-4

Wheel Alignment Inspection 9-5

Wheel Alignment Adjustment.... 9-5

Drive Chain Wear Inspection 9-5

Drive Chain Lubrication.... 9-6

Drive Chain Removal 9-6

Drive Chain Installation 9-7

Sprockets.... 9-8

Engine Sprocket Removal 9-8

Engine Sprocket Installation 9-8

Rear Sprocket Removal 9-8

Rear Sprocket Installation.... 9-8

Sprocket Wear Inspection.... 9-8

Rear Sprocket Warp Inspection 9-9

GK021268W4 C

1. EngineSprocket

2. OutputShaft

3.Swingarm

4.ChainSlipper

5.ChainGuide

6.Locknut

1. Adjusting Bolt

2. ChainAdjuster

9.DriveChain

10.RearSprocket

11.RearAxle

12.KX65-A6,A6F\~

T1:26N·m(2.7kgf·m,20ft·lb)

DriveChainSlackInspection

• Supportthemotorcycleonitsstand.
• Checkthewheelalignment(seeWheelAlignmentInspection), and adjustitifnecessary(seeWheelAlignmentAdjustment).

NOTE

○Cleanthedrivechainifitisdirty, and lubricateitifit appears dry.

• Rotatetherearwheeltofindthepositionwherethechain istightest.
• Measurethespace(chainslack)Abetweenthechain andtheswingarmattherearofthechainslipperwiththe rearwheelraisedofftheground.
  ★ Ifthedrivechainslackexceedsthestandard,adjustit.

ChainSlack

Standard:

KX65-A1\~

44\~54mm

A2

KX65-A3\~45\~55mm

DriveChainSlackAdjustment

• LoosentheleftandrightchainadjusterlocknutsA.

• Removethecotterpin[B]andloosentheaxlenut[C].
  ★ Ifthechainistootight,backouttheleftandrightchain adjustingbolts[D]evenly,andpushthewheelf forward untilthechainistooloose.
  ★ Ifthechainistooloose,turnbothchainadjustingbolts evenlyuntilthedrivechainhasthecorrect amountof slack.Tokeepthechainandwheelproperlyaligned,the rearendoftheleftchainadjustersshouldalignwiththe sameswingarmmark[E]astherearen d[F]oftheright chainadjuster.

• Checkthewheelalignment.

• Tightenbothchainadjusterlocknutssecurely.
• Tightentheaxlenu t.

Torque - Rear Axle Nut: 79 N·m (8.0 kgf·m, 58 ft·lb)

- InsertanewcotterpinA.

NOTE

When inserting the cotterpin, if the slots in then but do not align with the cotterpinhole in the axle, tighten the nut clockwise [B] uptonextalignment.

○Itshouldbewithin30degree.

○Loosenonceandtightenagainwhentheslotgoespast thenaresthole.

DriveChain

- BendthecotterpinAoverthenut[B].

- Rotatethewheel, measure the chainslack again at the tightest position, and readjustif necessary.

WARNING

Alooseaxlenutcanleadtoanaccidentresultingin seriousinjuryordeath. Tightentheaxlenuttothe propertorqueandinstallanewcotterpin.

NOTE

○ Inwetandmuddyconditions, mudstickstothecchain andsprocketsresultinginanoverlytightchain, and the chainmaybreak. Topreventthis, adjustthechainto54 \~ 64mm(KX65-A3 \~, 55 \~ 65mm)ofslackwhenever necessary.

WheelAlignmentInspection

- CheckthattherearendAoftheleftchainadjuster[B] alignswiththesameswingarmmark[C]astherightchain adjuster.

NOTE

○ Wheelalignmentcanalsobecheckedusingthe straightedgeorstringmethod.

WARNING

Misalignmentofthewheelwillresultinabnormal wearandmayresultinanunsaferidingcondition. Besurethewheelisproperlyaligned.

WheelAlignmentAdjustment

These procedures are the same as DriveChainSlack Adjustment.

DriveChainWearInspection

- Rotatetherearwheeltoinspectthedrivechainfordamagedrollers, and loosepinsandlinks.

ABushing

[B]Roller

[C]Pin

[D]PinLink

[E]RollerLink

★Ifthereisanyirregularity,replacethedrivechain.

★Lubricatethedrivechainifitappearsdry.

DriveChain

• Stretchthechaintautbyhanginga98N(10kg,20lb) weightAonthechain.
• Measurethelengthof20links[B]onthestraightpart[C]of thechainfromthepincenterofthe1stpintothepincenter ofthe21stpin.Sincethechainmaywearunevenly,take measurementsatseveralplaces.

Chain20-linkLength

Standard: 254.0\~254.6mm

ServiceLimit: 259mm

★ Ifanymeasurementsexceedtheservicelimit,replace the chain.Also,replacethefro ntandrearsprocketshenthe drivechainisreplaced.

WARNING

Achainthatbreaksorjumpsoffthesprockets couldsnagontheengin esprocketorlockthe rearwheel,severelydamagingthemotorcycleand causingittogooutofcontrol.Inspectthechainfor damageandpro peradjustmentbeforeeachride. Ifchainwearexceedstheservicelimit,replaceit withthestandardchain.

StandardChain

Make: DAIDO

Type: DID420MBK1

Link: 108Links

110Links(KX65-A3\~)

DriveChainLubrication

• If the chain appears especially dirty, it should be cleaned before lubrication with high flash-points solvent.
• Ifaspeciallubricantisnotavailable, aheavyoilsuchas SAE90 is preferred to alighteroil because it will stay on the chain longer and provide better lubrication.
• Applyoiltothesidesoftherollerssothatoilwillpenetrate totherollersandbushings.
  OilAppliedAreasA
• Wipeoffanyexcessoil.

DriveChainRemoval

• Removetheenginesprocketcover.
• RemovetheclipAfromthemasterlinkusingpliers,and freethedrivechainfromtherearsprocket.
• Removethedrivechainfromthechassis.

DriveChain

DriveChainInstallation

• Fitthedrivechainbackontothesprocketswiththeends attherearsprocket.
  • Installthemasterlinkfromtheframeside.
• InstalltheclipAsothattheclosedendofthe"U"[B] pointsinthedirectionofchainrotation[C].
• Adjustthedrivechainslack(seeDriveChainSlackAdjustment).
• Checktherearbrake(seetheBrakeschapter).

Sprockets

EngineSprocketRemoval

- Remove:

MagnetoCover

DriveChainA

- Removethecirclip[B], and pullofftheenginesprocket [C].

SpecialTool-OutsideCirclipPliers:57001-144

EngineSprocketInstallation

• Replacethecirclipwithanewone.
• Install the circlip so that the tooth is aligned with aspline groove.

SpecialTool-OutsideCirclipPliers:57001-144

RearSprocketRemoval

- Removetherearwheel(seeWheels/Tireschapter).

NOTICE

Donotlaythewheelonthegroundwiththedisc facingdown. This candamageofwarpthedisc. Placeblocksunderthewheelsothatthed iscdoes nottouchtheground.

- UnscrewtherearsprocketboltsA, andremovetherearsprocket[B].

RearSprocketInstallation

• Installtherea rsprocketAsothatthemarkedside[B] facesout.
• Tightentherearsprocketbolts.

Torque-RearSprocketBolts:26N·m(2.7kgf·m,20ft·lb)

SprocketWearInspection

• Visuallyinspectthefrontandrearsprocketteeth.
  ★ Iftheteetharewornasillustrated, replacethesprocket, and inspect the drivechain and engines procket (see DriveChainWearInspection).

WornTooth(EngineSprocket)A

WornTooth(RearSprocket)[B]

DirectionofRotation[C]

NOTICE

Ifasprocketrequiresreplacement,thedrivechain isprobablywornalso.Uponreplacingtherear sprocket,inspectthechainandenginesprocket.

Sprockets

RearSprocketWarpInspection

• Usingthejack, raisetherearwheelofftheground.

SpecialTool-Jack:57001-1238

- SetadialgaugeAagainsttherearsprocket[B]nearthe teethasshownandrotate[C]therearwheeltomeasure thesprocketrunout(warp). Thedifferencebetween the highestandlowestdialgaugereadingsistheamountof runout(warp).

★ Iftherunoutexceedstheservicelimit, replacetherear sprocket.

RearSprocketWarp

Standard:

Under0.4mm

ServiceLimit:

0.5mm

Brakes

TableofContents

Exploded View 10-2

Specifications 10-4

Brake Lever, Brake Pedal 10-5

Brake Lever Play Adjustment.... 10-5

BrakePedalPosition/PedalPlayAdjustment....10-5

Brake Pedal Removal 10-5

Brake Pedal Installation 10-6

Brake Fluid 10-7

Fluid Level Inspection 10-8

Fluid Change.... 10-8

Bleeding the Brake Line.... 10-10

Caliper 10-12

Caliper Removal 10-12

Caliper Installation 10-12

Caliper Disassembly 10-13

Caliper Assembly 10-13

Fluid Seal Damage Inspection.... 10-14

DustSealandCoverDamageInspection....10-14

Piston Cylinder Damage Inspection.... 10-14

Caliper Holder Shaft Wear Inspection.... 10-14

Brake Pad Removal 10-15

Brake Pad Installation 10-15

Brake Pad Inspection.... 10-15

Master Cylinder 10-16

Front Master Cylinder Removal 10-16

Front Master Cylinder Installation 10-16

Rear Master Cylinder Removal.... 10-17

Rear Master Cylinder Installation.... 10-17

Front Master Cylinder Disassembly 10-17

Rear Master Cylinder Disassembly.... 10-18

Master Cylinder Assembly 10-18

MasterCylinderInspection(VisualInspection)....10-19

Brake Disk 10-20

Brake Disc Inspection 10-20

Brake Hose.... 10-21

Brake Hose Removal/Installation 10-21

Brake Hose Inspection.... 10-21

1. FrontBrakeReservoir
   2.BrakeLever
2. BrakeHose
3. Clamps
   5.FrontCaliper
   6.BrakePad
4. Piston
   8.FrontDisc
   9.KX65A9F\~

T1:25N·m(2.5kgf·m,18ft·lb)
T2:8.8N·m(0.90kgf·m,78in·lb)
T3:7.8N·m(0.80kgf·m,69in·lb)
T4:18N·m(1.8kgf·m,13ft·lb)
T5:9.8N·m(1.0kgf·m,87in·lb)
T6:4.9N·m(0.50kgf·m,43in·lb)

L: Applyanon-permanentlockingagent.

R:ReplacementParts

Si:ApplySiliconegrease.

ExplodedView

1. RearBrakeReservoir
2. RearMasterCylinder
   3.BrakeHose
3. BrakePedal
4. RearCaliperCover
   6.RearCaliper
   7.Piston
   8.BrakePad
   9.RearDisc

T1:25N·m(2.5kgf·m,18ft·lb)

T2:9.8N·m(1.0kgf·m,87in·lb)

T3:7.8N·m(0.80kgf·m,69in·lb)

T4:18N·m(1.8kgf·m,13ft·lb)

G:Applyhightemperaturegrease.

L: Applyanon-permanentlockingagent.

R:ReplacementParts

Si:ApplySiliconegrease.

Specifications

Item	StandardServiceLimit
BrakeAdjustmentLeverPlayAdjustable(tosuitrider)-- --
BrakeFluidRecommendedDiscBrakeFluid:-- --Type	DOT3orDOT4	---
BrakePadsLiningThickness:Front4.5mm0.7mmRear4.5mm0.7mm
BrakeDiscThickness:Front2.80~ 3.20mm2.5mmRear2.80~ 3.20mm2.5mmRunoutNotmorethan0.15mm0.3mm

SpecialTools-InsideCirclipPliers:57001-143

Jack: 57001-1238

BrakeLever, BrakePedal

BrakeLeverPlayAdjustment

• AdjustthefrontbrakeleverAtosuityou.
• Slidethebrakeleverdustcover[B]outofplace.
• Loosentheadjusterlocknut[C]andturntheadjuster[D]toeitherside.
  • Afteradjustment, tightenthelocknut.

WARNING

Animproperlyadjustedbrakecoulddragandcause thebraketooverheat,damagingthebrakeassemblyandpossiblylockingtherearwheel,resultingin lossofcontrol.Alwaysmaintaintheproperbrake adjustment.

BrakePedalPosition/PedalPlayAdjustment

Thebrakepedalpositionandpedalplayshouldnotbe adjusted. Thereisnopedalpositionadjustmentdevice assuch. Theonlyadjustmentismastercylinderpushrod length.

NOTE

○ Usuallyitisnotnecessarytoadjustthepushrodlength, butalwaysadjustitwhentherearmastercylinderAis disassembled.
○ Whenthebrakepedalisinitsrestposition, measure thelength[B]indicatedinthefigure.

B:80.5mm

C:PushRodLocknut

★ Ifthelengthisnotwithinthespecifiedlength,adjustthe clevisAasfollows.
○Loosenthepushrodlocknut[B].
○Pulloutthecotterpin[C]andthejointpin[D].
○Turntheclevistoobtainthespecifiedlength.
○Tightenthelocknut.

Torque-PushRodLocknut:18N·m(1.8kgf·m,13ft·lb)

○Installthejointpinandnewcotterpin.

NOTE

○ Ifthepedalpositionisincorrectafteradjusting the mastercylinderpushrod, thebrakepedalmaybeformed orincorrectlyinstalled.

BrakePedalRemoval

• Remove: CotterPinA
  JointPin[B]
  Washer

GL04002BS1 C

GL04000BS1 C

10-6BRAKES

BrakeLever, BrakePedal

- RemovethebrakepedalmountingboltAandtakeoff thebrakepedalandreturnspring[B].

BrakePedallInstallation

- CheckthepedalO-ringforsignsofdamage.Ifnecessary, replacethemwithnewone. - Applyhightemperaturegreasetotheshaftportionofthe brakepedal,andinstallthepedalwithreturnspringonto theframe.

Torque-BrakePedalMountingBolt:25N·m(2.5kgf·m,18ft·lb)

• Checkthebrakepedalposition.
• Installthejointpin, washerandanewcotterpin.

WARNING

When working with the disc brake, observ the precautions listed below.

1. Neverreuseoldbrakefluid.
2. Donotusefluidfromacontainerthathasbeenleft unsealedorthathasbeenopenforalongtime.
3. Donotmixtwotypesandbrandsoffluidforusein thebrake. Thislowersthebrakefluidboilingpoint andcouldcausethebraketobeineffective. It may also cause therubberbrakepartstodeteriorate.
4. Don'tleavethereservoircapofforanylengthof timetoavoidmoisturecontaminationofthefluid.
5. Don't changethe fluid in therain or when a strong windis blowing.
6. Except forthediscpadsanddisc, use only disc brake fluid, isopropyl alcohol, orethyl alcohol for cleaning brake parts. Donot 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 while eventually deteriorate the rubber used in the disc brake.
7. When handling the discpadsordisc, be careful that nodiscbrakefluidoranyoilgetsonthem. Cleanoff any fluidorolthatinadvertently gets on the pads or disc with a high flash-points solvent. Donotuseone which will leave an oily residue. Replacethepads with new ones if they cannot be cleaned satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any spilledfluidshouldbecompletelywipedupimmediately.
9. If any of the brakeline fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE BRAKELINE.

BrakeFluid

FluidLevelInspection

Inaccordance with the Periodic Maintenance Chart, inspect the brake fluid level in the front and rear brake fluid reservoirs.

- CheckthebrakefluidlevelinthefrontbrakereservoirA.

NOTE

○Holdthereservoirhorizontalwhencheckingbrakefluid level.

○Thefrontreservoirmustbekeptabovethelowerlevel line[B]. If the fluid level in frontreservoir is lower than the lower level line, fill the reservoir to the upper level line. Inside the frontreservoir is stopped and showing the upper level line[C].

- TherearreservoirAmustbekeptmorethanhalffullwith brakefluid.Iftheamountofbrakefluidisinsufficient,add brakefluid.

Close-up of a mechanical component with a labeled section marked 'A' (no readable text or symbols beyond the label)

FluidChange

InaccordancewiththePeriodicMaintenanceChart, changethebrakefluid. Thebrakefluidshouldalsobe changedifitbecomescontaminatedwithdirtorwater. Furthermore, thebrakefluidshouldbechangedtobleed theairquicklyandcompletelywheneverthebrakeline partsareremoved.

WARNING

Mixingbrandsandtypesofbrakefluidcanreduce thebrakesystem'seffectivenessandcauseanaccidentresultinginjuryordeath.Donotmixtwo brandsofbrakefluid.Changethebrakefluidinthe brakelinecompletelyifthebrakefluidmustbere-filledbutthetypeandbrandofthebrakefluidthat isalreadyinthereservoirareunidentified.

RecommendedDiscBrakeFluid

Type:

DOT3orDOT4

BrakeFluid

NOTE

○ Theproceduretochangethefrontbrakefluidisasfollows. Changingtherearbrakefluidisthesameasfor thefrontbrake.

- Levelthebrakefluidreservoir.

- Removethereservoircap.

- RemovetherubbercapAonthebleedvalve[B].

- Attachaclearplastichosetothebleedvalveonthe caliper, and run the other end of the hose into a container.

- Changethebrakefluidasfollows:

○Repeatthisoperationuntilfreshbrakefluidcomesout fromtheplastichoseorthecolorofthefluidchanges.

1. OpenthebleedvalveA

2.Applythebrakeandholdit[B]

1. Closethebleedvalve[C]

2. Releasethebrake[D]

○Fillthereservoirwithfreshspecifiedbrakefluid.

NOTE

○ Thefluidlevelmustbecheckedoftenduringthechangingoperationandreplenishedwithfreshbrakefluid. If thefluidinthereservoirrunsoutanytimeduringthe changingoperation,thebrakeswillneedtobebled sinceairwillhaveenteredthebrakeline.

- Removetheclearplastichose.

- Tightenthebleedvalves, and installtherubbercap.

Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb)

- Afterchangingthefluid, checkthebrakeforgoodbraking power, nobrakedrag, andnofluidleakage.

★Ifnecessary,bleedtheairfromthelines.

• Installthereservoircap.

NOTE

○ Follow the procedure below to install therear brake reservoir cap correctly.

○ First, tightentherearbrakereservoircap[B]clockwise [C]byhanduntilslightresistanceisfeltindicatingthat thecapsseatedonthereservoirbody, thentightenthe capanadditional1/6turn[D]whileholdingthebrake fluidreservoirbodyA.

BrakeFluid

BleedingtheBrakeLine

Thebrakefluidhasaverylowcompressioncoefficientso thatalmostallthemovementofthebrakeleverorpedal istransmitteddirectlytothecaliperforbrakingaction.Air, however,iseasilycompressed.Whenairentersthebrake lines,brakeleverorpedalmovementwillbepartiallyused incompressingtheair.Thiswillmaketheleverorpedalfeel spongy,andtherewillbealossinbrakingpower.

WARNING

Airinthebrakelinesdiminishbrakingperformance andcancauseanaccidentresultinginjuryor death.Ifthebrakeleverhasasoftor"spongy"feelingmushywhenitisapplied,theremightbeairin thebrakelinesorthebrakemaybefective.Do notoperatethevehicleandservicethebrakesystemimmediately.

NOTE

○Theproceduretobleedthefrontbrakelineisasfollows. Bleedingtherearbrakelineisthesameasforthefront brake.

- Removethereservoircap, and check that there is plenty off fluid in the reservoir. - With the reservoir cap off, slowly pump the brake lever severaltimes until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir.

○ Bleedtheaircompletelyfromthemastercylinderbythis operation.

• Installthereservoircap.

- Attachaclearplastichosetothebleedvalveonthe caliper, and run the other end of the hose into a container.

- Bleedthebrakelineandthecaliperasfollows:

○ Repeat this operation until nomore air can be seen coming out into the plastic chose.

1. Pumpthebrakeleveruntilbecomeshard, and apply thebrakeandholditA.
2. Quickly open and closethe bleed valve while holding the brake applied [B].
3. Releasethebrake[C].

NOTE

○Thefluidlevelmustbecheckedoftenduringthebleedingoperationandreplenishedwithfreshbrakefluidas necessary. Ifthefluidinthereservoirrunsalmostout anytimeduringbleedingoperation,thebleedingoperationmustdoneoveragainfromthebeginningsince airwillhaveenteredtheline.
○ Tapthebrakehoselightlyfromthecalipertothereservoirforeasierbleeding.

BrakeFluid

• Removetheclearplastichose.
• Tightenthebleedvalves, and installtherubbercap.
  Torque-CaliperBleedValve:7.8N·m(0.8kgf·m,69in·lb)
• Checkthefluidlevel.
• Afterbleedingisdone, checkthebrakeforgoodbraking power, nobrakedrag, andnofluidleakage.

WARNING

Afterservicing, ittakesseveral applications of the brakelever before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Donot attempt toridethemotor cycle until a firm brake lever is obtained by pumping the lever until the pads are against the disc.

Caliper

CaliperRemoval

FrontBrake

• LoosenthebanjoboltAsoasnottospillbrakefluid.
• Removethecalipermountingbolts[B].
• Removethebanjoboltandtakeoffthebrakehosefrom thecaliper[C].
• Ifthecaliperistobedisassembledafterremovalandif compressedairisnotavailable,removethepistonusing thefollowingstepsbeforedisconnectingthebrakehose fromthecaliper.
  ○Removethepads.
  ○Pumpthebrakelevertoremovethepiston.

RearBrake

• Unbolttheguardboltsandremovetherearcaliperguard.
• LoosenthebanjoboltAsoasnottospillbrakefluid.
• Removethecalipermountingbolts[B].
• Removethebanjoboltandtakeoffthebrakehosefrom thecaliper[C].
• Ifthecaliperistobedisassembledafterremovalandif compressedairisnotavailable,removethepistonusing thefollowingstepsbeforedisconnectingthebrakehose fromthecaliper.
  ○Removethepads.
  ○Pumpthebrakelevertoremovethepiston.

NOTICE

Immediatelywipeupanybrakefluidthatisspilled.

CaliperInstallation

• Tightenthebrakepadbolt siftheywereremoved.
  Torque-BrakePadBolts:18N·m(1.8kgf·m,13ft·lb)
• Installthecaliper, and the brakehoselowerend.
  ○Replacethewasherstha tareoneachsideofhosefitting withnewones.
  ○Installthebrakehoselowerendsothatthewhitepaint markonitfacesbac kward.

Torque-CaliperMountingBolts:25N·m(2.5kgf·m,18ft·lb) BrakeHoseBanjoBolt:25N·m(2.5kgf·m,18ft·lb)

• Bleedthebrakeli ne(seeBleedingtheBrakeLine).
• Checkthebrakeforgoodbrakingpower,nobrakedrag, andnofluidleakage.

WARNING

Afterservicing, ittakesseveral applications of the brakeleverorpedal before the brakepads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Donot attempt toridethemotorcycle until a firm brake leverorpedalis obtained by pumping the leverorpedal until the pads are again sthedisc.

Caliper

CaliperDisassembly

• Removethefront/rearcaliper(seeCaliperremoval).
• Removethepadsandspring(seePadRemoval).
• Removethecaliperholder, shaftrubberfrictionbootand cover.
• Usingcompressedair,removethepiston(s).
  ○Coverthecaliperopeningwithaclean,heavyclothA.
  ○Removethepiston(s)bylightlyapplyingcompressedair [B]tothehosejointopening.

Close-up of a mechanical device with labeled parts A and B, no visible text or symbols on the main subject.

WARNING

Thepistoninthebrakecalipercancrushhandsand fingers. Neverplaceyourhandorfingersinfrontof thepiston.

NOTE

○ Ifthecaliperistobedisassembledafterremovaland compressedairisnotavailable,removethepiston(s) usingthefollowingthreestepsbeforedisconnectingthe brakehosefromthecaliper.

○Prepareacontainerforbrakefluid, and perform the workaboveit.

○Removethepadsandspring(seePadRemoval).

○Pumpthebrakeleverorpedaltoremovethecaliper piston(s).

• Removethedustseal(s)andfluidseal(s).
• Removethebleedvalveandrubbercap.

CaliperAssembly

- Cleanthecaliperpartsexceptforthepads.

NOTICE

Forcleaningtheparts, useonlydiscbrakefluid, isopropylalcohol, orethylalcohol.

- Tightenthebleedvalvewithrubbercap. Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb)

• Replacethefluidsealwhichisremovedwithnewone. ○Applybrakefluidtothefluidseal[B], andinstallitintothe cylinderbyhand.
• Replacethedustsealwithnewoneifitisdamaged.
  ○ApplybrakefluidtothedustsealA, and installitintothe cylinderbyhand.
• Applybrakefluidtotheoutsideofthepiston[C], and push it into the cylinder by hand.

Caliper

• Installtheanti-rattlespringAinthecaliperasshown.

Mechanical component with labeled section A, no visible text or symbols

• Replacetheshafrubberbootanddustcoveriftheyare damaged.
• Applyathincoatosiliconegreasetothecaliperholder shaftsandholderholes(PBCisaspecialhightemperature,water-resistantgrease).
  • Installthepads(seePadsInstallation).
• Wipeupanyspilledbrakefluidonthecaliper.

FluidSealDamageInspection

Thefluidsealaroundthepistonmaintainstheproper pad/discclearance.Ifthissealisnotingoodcondition, padwearwillincrease,andconstantpaddragonthedisc willraisebrakeandbrakefluidtemperature.

- Replacethefluidsealsunderanyofthefollowingconditions:(a)fluidleakagearoundthepad;(b)brakesoverheat;(c)thereisalargedifferenceinleftandrightpad wear;(d)thesealisstucktothepiston.Ifthefluidsealis replaced,replacethedustsealaswell.Also,replaceall sealseveryothertimethepadsarechanged.

DustSealandCoverDamageInspection

• Check that the dust seals and covers are not cracked, worn, swollen, or other wisedamaged.
  ★ Iftheyshowanydamage, replacethem.

PistonCylinderDamageInspection

- Visually inspect the piston and cylinders surfaces.

★Replacethecylinderandpistoniftheyarebadlyscored orrusty.

CaliperHolderShaftWearInspection

Thecaliperbodymustslidessmoothlyonthecaliperholder shafts.Ifthebodydoesnotslidessmoothly,onepadwill wearmorethantheother,padwearwillincrease,andconstantdragonthediscwillraisebrakeandbrakefluidtemperature.

• Checktoseeifthecaliperholdershaftsarenotbadlyworn orstepped,ortherubberbootisnotdamaged.
  ★ Iftheshaftsorrubberbootaredamaged,replace the shafts,rubberboot,andthecaliperholder.

Caliper

BrakePadRemoval

• LoosenthepadboltsA.
• Removethecaliper[B].
• Removethepadbolts.
  •Takeoutthepistonsidepad.
• Pushthecaliperholdertowardthepiston, and thenremoveanotherpadfromthecaliperholder.

BrakePadInstallation

• Pushthecaliperpistonsinbyhandasfarastheywillgo.
• InstallthepistonsidepadAfirst,andthenanotherpad[B].
• Tightenthebrakepadbolt.
  Torque-BrakePadBolts:18N·m(1.8kgf·m,13ft·lb)
• Checkthebrakeforgoodbrakingpower,nobrakedrag, andnofluidleakage.

WARNING

Afterservicing, ittakesseveral applications of the brakeleverorpedal before the brakepads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Donot attempt toridethemotorcycle until a firm brake leverorpedalis obtained by pumping the leverorpedal until the pads are again sthedisc.

BrakePadInspection

• Checktheliningthicknessandconditionofthepadsineachcaliper.
  ★lfeitherpadisdamaged,replacebothpadsinthecaliper asaset.
  ★ IftheliningthicknessAofeitherpadislessthanthe servicelimit[B],replacebothpadsinthecaliperasaset.

LiningThickness

Standard:

Front4.5mm

Rear4.5mm

ServiceLimit:

Front0.7mm

Rear0.7mm

Two mechanical component diagrams labeled A and B, showing different mounting features with directional arrows (no text or symbols beyond labels)

NOTICE

Brakefluidquicklyruinspaintedorplasticsurfaces;anyspilledfluidshouldbecompletelywiped upimmediately.

FrontMasterCylinderRemoval

• RemovethebanjoboltAtodisconnecttheupperbrake hosefromthemastercylinder(seeBrakeHoseRemoval/Installation).
• When removing the brakehose, temporarily secure the endofthe brakehosetosome high placeto keep fluid lossto a minimum.
• Unscrewthemastercylinderclampbolts[B], and takeoff themastercylinder[C] as an assembly with the reservoir and brakelever.

FrontMasterCylinderInstallation

- Positionthemastercylindersothatthepartingli neAof themastercylinderclampalignwiththepunchmark[B] onthehandlebar.

• ThemastercylinderclampmustbeinstalledwiththearrowmarkAupward.
  ○ Tightentheupper clampbolt[B]first, and thenthelower clampbolt[C]Therewillbeagapatthelowerpartofthe clampaftertightening.

Torque-MasterCylinderClampBolts:8.8N·m(0.9kgf·m, 78in·lb)

• Replacethewashersthatareoneachsideofhosefitting withnewo nes.
• Tightenthebrakehosebanjobolt.

Torque-BrakeHoseBanjoBolt:25N·m(2.5kgf·m,18ft·lb)

- Bleedt hebrakeline(seeBleedingtheBrakeLine).

- Checkthebrakeforgoodbrakingpower,nobrakedrag, andnofluidleakage.

MasterCylinder

RearMasterCylinderRemoval

• Removetherightsidecoverandthereservoirmounting boltA.
• Removethecotterpin[B].
• Pulloffthejointpin[C]withwasher.

NOTE

○ Pulloffthejointpinwhilepressingdownthebrake pedal.

• UnscrewthebrakehosebanjoboltD.
• When removing the brakehose, temporarily secure the endofthe brakehosetosome high placeto keep fluid lossto a minimum.
• Unscrewthemastercylindermountingbolts[E], andremovethemastercylinder[F] withthereservoir.
• Removethereservoircap, and pour the brake fluid into a container.
• Removethereservoiranditshosefromthemastercylinder.

RearMasterCylinderInstallation

• Replacethecotterpinwithanewone.
• Replacethewashersareoneachsideofhosefittingwith newones.
• Tightenthefollowing:

Torque-MasterCylinderMountingScrews:9.8N·m(1.0 kgf·m,87in·lb)

Brake Hose Banjo Bolt: 25N·m(2.5kgf·m,18ft·lb)

• Bleedthebrakeline(seeBleedingtheBrakeLine).
• Checkthebrakeforgoodbrakingpower,nobrakedrag, andnofluidleakage.
• Checkthebrakepedalposition(mastercylinderpushrod length).

FrontMasterCylinderDisassembly

• Removethefrontmastercylinder.
• Removethereservoircapanddiaphragm, and pour the brakefluid into a container.
• Unscrewthelocknutandpivotbolt, andremovethebrake lever.
• PushthedustcoverAoutofplace,andremovethecirclip[B].

SpecialToo I - InsideCirc lipPliers:57001-143

- Removethewasher[C], pulloutthepiston[D], primary cup[F], and returnspring[G].

NOTICE

Donotremovethesecondarycup[E]fromthepistonsinceremovalwilldamageit.

RearMasterCylinderDisassembly

• Removetherearmastercylinder.
• SlidethedustcoverAonthepushrod[B]outofplace, andremovetheretainer[C].
  SpecialTool-InsideCirclipPliers:57001-143
• Pulloutthepushrodwiththepistonstop[D].
• Takeoffthepiston[E], primarycup[G], and returnspring [H].

NOTICE

Donotremovethesecondarycup[F]fromthepistonsinceremovalwilldamageit.

- Removethecirclip[I], and takeofftheconnector[J] and O-ring[K].

MasterCylinderAssembly

• Beforeassembly, cleanallpartsincludingthemaster cylinderwithbrakefluidoralcohol.
• Applybrakefluidtotheremovedpartsandtotheinner wallofthecylinder.

NOTICE

Exceptforthediscpadsanddisc,useonlydisc brakefluid,isopropylalcohol,orethylalcoholfor cleaningbrakeparts.Donotuseanyotherfluidfor cleaningtheseparts.Gasoline,engineoil,orany otherpetroleumdistillatewillcausedeteriorationof therubberparts.Oilspilledonanypartwillbedifficulttowashoffcompletely,andwilleventuallydeterioratetherubberusedinthediscbrake.

• Takecarenottoscratchthepistonortheinnerwallofthe cylinder.
• Tighten the brake lever pivot bolt and the locknut securely.
  Torque-RearMasterCylinderPushRodLocknut:18N·m (1.8kgf·m,13ft·lb)

MasterCylinder

MasterCylinderInspection(VisualInspection)

• Disassemblethefrontandrearmastercylinders.
• Check that there are nos scratches, rust or pitting on the inner wallofeach master cylinder A and on the outside of each piston [B].
  ★Ifamastercylinderorpistonshowsanydamage,replace them.
• Inspecttheprimary[C]andsecondary[D]cups.
  ★Ifacupisworn,damaged,softened(rotted),orswollen, thepistonassemblyshouldbereplacetorenewthecups.
  ★Iffluidleakageisnotedatthebrakelever,thepistonassemblyshouldbereplacedtorenewthecup.
• Checkthedustcovers[E]fordamage.
  ★Iftheyaredamaged, replacethem.
• Check that therelief[G] and supply[H] ports are not plugged.
  ★Ifthesmallreliefportbecomesplugged,thebrakepads willdragonthedisc.Blowtheportscleanwithcompressedair.
• Checkthepistonreturnsprings[F]foranydamage.
  ★Ifaspringisdamaged,replaceit. [J]FrontMasterCylinder [K]RearMasterCylinder

BrakeDisk

BrakeDisclInspection

• VisuallyinspectthediscA.
  ★ Ifitisscratchedordamaged, replacethedisc.
• Measurethethicknessofeachdiscatthepoint[B]where ithaswornthemost.
  ★Replacethediscifithaswornpasttheservicelimit.

Thickness

Standard:

Front2.80\~3.20mm

Rear2.80\~3.20mm

ServiceLimit:

Front2.5mm

Rear2.5mm

Torque-BrakeDiscMountingBolts:9.8N·m(1.0kgf·m,87in·lb)

• Placeajackunderthemotorcyclesothatthefront/rear wheelisraisedofftheground.
  SpecialTool-Jack:57001-1238
• SetupadialgaugeagainstthediscAasillustrated.
  ○Forthefrontdisc,turnthehandlebarfullytooneside.
• Measurethediscrunoutwhilerotatingthewheelslowly [B].
  ★ Iftherunoutexceedstheservicelimit,replacethedisc.

Runout

Standard: Notmorethan0.15mm

ServiceLimit:0.3mm

BrakeHose

BrakeHoseRemoval/Installation

NOTICE

Brakefluidquicklyruinspaintedorplasticsurfaces;anyspilledfluidshouldbecompletelywiped upimmediatelywithwateredcloth.

• When removing the brakehose, take care not to spill the brake fluid on the painted or plastic parts.
• When removing the brakehose, temporarily secure the endofthe brakehosetosome high placeto keep fluid lossto a minimum.
• Therearewashersoneachsideofthebrakehosefitting. Replacethemwithnewoneswheninstalling.
• Wheninstallingthehoses,avoidsharpbending,kinking, flatteningortwisting,androutethehosesaccording to theCable,WireandHoseRoutingsectionintheGeneral Informationchapter.
• Torquethebanjoboltsatthehosefittings.

Torque-BrakeHoseBanjoBolts:25N·m(2.5kgf·m,18 ft·lb)

- Bleedthebrakelineafterinstallingthebrakehose(see BleedingtheBrakeLine).

BrakeHoselnspection

- The high pressure insidethebrakeline can cause fluid to leak A or the host of burst theline is not properly maintained. Bend and twist the rubber hose while examining it.

★Replaceitifanycracks[B]orbulges[C]arenoticed

Suspension

TableofContents

Exploded View.... 11-2

Specifications 11-6

Front Fork 11-7

Rebound Damping Adjustment (KX65-A3 \~) 11-7

Fork Oil Level Adjustment (Simplify).... 11-7

OilChange/OilLevelAdjustment(eachforkleg)....11-9

Front Fork Removal 11-10

Front Fork Installation 11-11

Front Fork Disassembly (each fork).... 11-11

Front Fork Assembly (each fork).... 11-13

Inner Tube Inspection 11-14

Guide Bush Inspection.... 11-14

Dust Seal/Oil Seal Inspection 11-14

Spring Tension Inspection.... 11-14

Rear Suspension (Uni-Trak) 11-15

Rear Shock Absorber 11-15

ReboundDampingForceAdjustment....11-15

Spring Preload Adjustment 11-15

Rear Shock Absorber Removal 11-16

Rear Shock Absorber Installation 11-17

Spring Replacement 11-17

Spring Tension 11-18

Rear Shock Absorber Scrapping 11-18

Swingarm.... 11-19

Swingarm Removal 11-19

Swingarm Installation.... 11-19

Swingarm Bearing Removal 11-19

Swingarm Bearing Installation 11-20

Tie-rod, Rocker Arm 11-21

Tie-rod Removal 11-21

Tie-rod Installation 11-21

Rocker Arm Removal.... 11-21

Rocker Arm Installation.... 11-22

Needle Bearing Inspection.... 11-22

Uni-Trak Maintenance 11-23

Rocker Arm Sleeve Wear Inspection 11-23

Rocker Arm Mounting Bolt Bend Inspection 11-23

GM02006BW4 C

ExplodedView

1.TopPlug
2.O-ring
3.ForkSpring
4. Piston Cylinder Unit
5. InnerTube
6.GuideBushes
7.DustSeal
8.RetainingRing
9.OilSeal
10.Washer
11. OuterTube
12.Gasket
13. AllenBolt
14. SteeringStemHead
15. SteeringStem
16.SpringSeat
17.KX65-A3\~
T1:22N·m(2.2kgf·m,16ft·lb)
T2:20N·m(2.0kgf·m,14ft·lb)
T3:29N·m(3.0kgf·m,22ft·lb)
T4:44N·m(4.5kgf·m,33ft·lb)
L: Applyanon-permanentlockingagent.

ExplodedView

1.PivotShaft
2.Swingarm
3.RockerArm
4. Tie-rod
5. RearShockAbsorber
6.RearShockAbsorber(KX65-A3\~)
T1:69N·m(7.0kgf·m,51ft·lb)
T2:83N·m(8.5kgf·m,61ft·lb)
T3:59N·m(6.0kgf·m,43ft·lb)
T4:34N·m(3.5kgf·m,25ft·lb)
T5:39N·m(4.0kgf·m,29ft·lb)
G:Applygrease.
L: Applyanon-permanentlockingagent.

Specifications

Item	StandardServiceLimit
FrontFork
OilViscositySHOWASS-8orequivalent- - - OilCapacity(CompletelyDry)238±2.5mL(KX65-A1)- - - OilLevel(FullyCompressed, SpringRemoved)	240±2.5mL(KX65-A2)	- - -
	252±2.5mL(KX65-A3~)	- - -
	124±2mm(KX65-A1) (fromtopofinnertube)	98~ 140mm(KX65-A1)
	126±2mm(KX65-A2) (fromtopofinnertube)	96~ 139mm(KX65-A2)
	132±2mm(KX65-A3~) (fromtopofinnertube)	98 ~ 142 mm (KX65-A3 ~)
ForkSpringFreeLength455.7mm(KX65-A1)446.6mm(KX65-A1)	470.7mm(KX65-A2)461.3mm(KX65-A2)	487.2 mm (KX65-A3 ~)
	497.1 mm (KX65-A3 ~)
RearSuspension(Uni-Trak)
RearShockAbsorber(AdjustableRange)
Spring Preload Adjustment	88.8 mm (KX65-A1)	82.8 ~ 94.8 mm (KX65-A1 ~ A2)
(Adjustingnutpositionfromthe 866.6mm(KX65-A2) center of the upper mounting hole)	79.6 mm (KX65-A3 ~ A6)	75.6 ~ 83.6 mm (KX65-A3 ~ A6)
	80.1 mm (KX65A6F ~)	76.1 ~ 84.1 mm (KX65A6F ~)
Rear Shock Spring Free Length	206.1 mm	202.0 mm
	211.1 mm (KX65-A3 ~)	206.9 mm (KX65-A3 ~)
GasReservoir
GasPressure	980kPa(10kgf/cm2,142psi)	- - -
Tie-rod,RockerArm
Sleeve Outside Diameter	17.989 ~ 18.000 mm	17.96 mm
Rocker Arm Mounting Bolt Runout	under 0.1 mm	0.2 mm

Special Tools - Fork Cylinder Holder Handle: 57001-183

ForkCylinderHolderAdapter: 57001-1011

OilSeal&BearingRemover:57001-1058

HookWrench:57001-1101

BearingDriverSet:57001-1129

ForkOuterTubeWeight: 57001-1218

ForkOilSealDriver:57001-1219

Jack: 57001-1238

ForkOilLevelGauge:57001-1290

FrontFork

Thefrontforkshouldalwaysbeadjustedfortherider's weightandtrackconditionsbyusingoneormoreofthe followingmethods.

Oilleveladjustment-Theeffectsofhigherorlowerfork oillevelareonlyfeltduringthefinal100mmofforktravel. Ahigheroillevel(moreoil)willmaketheforkrepulsion morelarge.Aloweroillevel(lessoil)willmakethefork repulsionmoresmall.
OForksprings-Optionalspringsareavailablethatare softerandstifferthanstandard.
○Forkclampposition-Steeringqualitiesaregreatlyaffectedbytheforkclampposition.Forktubeheightis theamountoftheinnertubeprojectingabovethesteeringstemhead.Whenthefortubeheightissmaller,the frontendbecomeslighterduetothechangeinweight bias.Also,ittendstoundersteerinturnsand"washout". Whentheheightisgreater,theresultsareopposite.

ReboundDampingAdjustment(KX65-A3 \~)

- Toadjustrebounddamping,turntheadjusterAonthe frontforktopplugswiththebladeofascrewdriveruntil youfeelaclick.Adjusttherebounddampingtosuityou preferenceunderspecialcondition.

NOTICE

Theleftandrightforklegsmusthavethesame shockdamping.

Seatedpositions: adjuster turned fully clockwiseA.

ReboundDampingAdjusterSetting

Standard: 3 clicks

graph LR
    A["Harder"] --> B{STD}
    B --> C["4"]
    B --> D["3"]
    B --> E["2"]
    B --> F["1"]
    G["Softer"] --> H["(Clockwise)"]
    H --> I["(Counterclockwise)"]
    I --> J["A"]

ForkOilLevelAdjustment(Simplify)

• Raisethefrontwheeloffthegroundusingajack.
  SpecialTool-Jack:57001-1238
• Removethenumberplate.
• Remove the front fork top plugs A and the fork spring [B].

FrontFork

KX65-A3\~

- Remove:

NumberPlate

HandlebarAssembly

FrontForkTopPlugA

ForkSpring[B]

ForkSpringSeat[C]

• Slowlycompress the front fork fully bypassing up the outertubes A using a jack or others suitable means under the front wheel.
• Placeastandorothersuitablesupport[B]underthefront wheel.

- Usetheoillevelgaugetomeasuretheforkoillevel.

With the fork fully compressed, put the oil level gauge A and the stopper [B], and adjusted distance from the top of the inertubetool.

SpecialTool-ForkOilLevelGauge:570 01-1290

FrontForkOilLevel(ful lycompressed, withoutspring) Standard: 124±2mm(KX65-A1)

126±2mm(KX65-A2)

132±2mm(KX65-A3\~)

AdjustableRange: 98\~140mm(KX65-A1)

96\~139mm(KX65-A2)

98\~142mm(KX65-A 3\~)

★ Ifnooilisdrawnout, thereisinsufficientoilinthefork tube. Pourinenoughoil, thenpumpouttheexcessoil.

ForkOil:

SHOWASS-8orequivalent

- Measurethebothdiametersoftheforkspringendsand inserttheforkspringwiththesmalldiameterendAfacingdown.

Mechanical assembly diagram showing a wheel mounted on a platform with labeled parts A and B (no text or symbols beyond labels)

Diagram of a coiled spring with a rectangular base and labeled point A (no text or symbols beyond label)

FrontFork

- CheckbothtopplugO-ringAfordamageandreplace themifnecessary.

Close-up of a mechanical assembly with labeled component A (no readable text or symbols)

• Installtheforktopplug.
• Installtheforktopplugandforspringseat(KX65-A3\~).
- Tightentheforktopplug.
Torque-FrontForkTopPlug:22N·m(2.2kgf·m,16ft·lb)
- Assembletheotherforktubeinthesamewayasdescribedabove.
• Installthepartsremoved.
- Installthehandlebarassembly(seeSteering).: KX65-A3\~

OilChange/OilLevelAdjustment(eachforkleg)

• Removethefrontfork(seethischapter).
• Removethefollowing. TopPlug
  ForkSpring
  ForkSpringSeat(KX65-A3\~)

WARNING

Thetopplugsareunderextremespringpressure andmayejectwithgreatforceduringservice.Use carewhenremovingthetopplugs.Weareyeand faceprotection.

• Holdtheforktubeupsidedownoveracleancontainer andpumpittodraintheoil.
• Fillthefrontforktothetopwithspecifiedoil.

RecommendedOil SHOWASS-8orequivalent

FrontForkOilCapacity(completelydry) 238±2.5mL(KX65-A1) 240±2.5mL(KX65-A2) 252±2.5mL(KX65-A3\~)

FrontFork

• Adjusttheoillevel.
  With the fork fully compressed, put the oil level gauge A and the stopper [B], and inspect the distance from the top of the inertubeto the oil.

SpecialTool-ForkOilLevelGauge:57001-1290

OilLevel(fullycompressed, withoutspring) Standard: 124±2mm(KX65-A1)

126±2mm(KX65-A2)

132±2mm(KX65-A3\~)

AdjustableRange: 98\~140mm(KX65-A1)

96\~139mm(KX65-A2)

98 \~ 142 mm (KX65-A3 \~)

★ Ifnooilisdrawnout, thereisinsufficientoilinthefork tube. Pourinenoughoil, thendrawnouttheexcessoil.
- Installthepartsr emoved(seeFrontForkAssembly)

FrontForkRemoval

• RemovethefrontbrakehoseclampsA.
• Removethecaliper[B]fromtheforklegtoberemoved, andrestthecaliperonsomekindofstandsothatitdoesn't dangle.
• Removethefrontwheel(seeWheels/Tireschapter).

Close-up of a bicycle wheel with visible tire, disc, and head assembly (no text or symbols)

• Removethenumberplate.
• LoosentheupperandlowerforkclampboltsA.
• Withatwistingmotion,worktheforklegdownandout.

Mechanical assembly diagram showing linkage components and labeled parts (A), no readable text or symbols present.

FrontFork

FrontForkInstallation

• Iftheforklegwasdisassembled, checktheforkoillevel.
• InstalltheforksothatthetopendAoftheinnertubeis 10mmup[B]withtheuppersurface[C]ofthesteering stemhead.
• InstalltheforksothatthetopendAoftheinnertubeis 20mmup[B]withtheuppersurface[C]ofthesteering stemhead(KX65-A3\~).
• RoutethecablesandhoseaccordingtotheCable, Wire and HoseRoutingsectionintheGeneralInformation chapter.
  • Installthefrontwheel(seeWheels/Tireschapter).
• Tightenthefollowing:

Torque-FrontForkClampBolts(Upper):20N·m(2.0 kgf·m,14ft·lb) FrontForkClampBolts(Lower):29N·m(3.0 kgf·m,22ft·lb) CaliperMountingBolts:25N·m(2.5kgf·m,18ft·lb)

- Checkthefrontbrakeoperationafterinstallation.

FrontForkDisassembly(eachfork)

• Removethefrontfork(seethischapter).
• Removethetopplugandtheforkspring.
• Draintheforkoilwiththeforkupsidedown(seeForkOil Change)
• HoldtheoutertubeAinavise.
• Stopthecylinder[B]fromturningbyusingthefrontfork cylinderholder.

SpecialTools-ForkCylinderHolderHandle:57001-183[C] ForkCylinderHolderAdapter:57001-1011[D]

- UnscrewtheAllenbolt[E], thentaketheboltandgasket outofthebottomoftheoutertube.

KX65-A3\~

• Loosenthetopplug.
• Removethefrontfork(seethischapter).
• HoldtheoutertubeAinavise.
• Holdoftheinnertube[B]andloosentheAllenbolt[C].
• Removethetopplug, theforkspringseatandforspring (seeForkOilLevelAdjustment).
• Draintheforkoilwiththeforkupsidedown(seeForkOil Change)
  • TakeouttheAllenbolt[C]andgasket.

11-12 SUSPENSION

FrontFork

- RemovethecylinderunitAandspring[B]fromthefork.

- RemovethedustsealAandretainingring[B].

- UsetheforkoutertubeweightAtoseparatetheinner tubefromtheoutertube. SpecialTool-ForkOuterTubeWeight:57001-1218

○ Holdingtheinnertubebyhandinaverticalposition,pull downtheoutertubeseveraltimestopullouttheinner tube.

- TheoilsealA, washer[B], and guidebushes[C] come off with the innertube. - Takethecylinderbase out of the outertube.

FrontFork

FrontForkAssembly(eachfork)

• Assemblyisthereverseofdisassembly.
• Replacethefollowingpartsremovedwithanewone.
  GuideBushes
  OilSeal
  BottomAllenBoltGasket

- Inspect the following and replace them with new ones if damaged.

InnerTube(seeInnerTubeInspection)

TopPlugO-ring

- Insertthecylinderunitandspringintheinnertube.

- InsertthecylinderbaseAinthecylinderunit[B].

○Thecylinderbasemustbeinstalledwiththetaperedside facingupward.

- Installthecylinderunitintheinnertubeandthecylinder baseinthebottomoftheoutertube.

- Applyanon-permanentlockingagenttothebottomAllen boltandtightenittothespecifiedtorque,usingthefront forkcylinderholder.

Torque-ForkBottomAllenBolts:20N·m(2.0kgf·m,14ft·lb)

SpecialTools-ForkCylinderHolderHandle:57001-183

(use for KX65-A1 \~ A2)

ForkCylinderHolderAdapter: 57001-1011

(use for KX65-A1 \~ A2)

- InstalltheguidebushAbytapping[C]theusedguidebushwiththeforkoilseal driver[D]untilitstops.

SpecialTool-ForkOilSealDriver:57001-1219

• Installthefollowing.
  Washer
  OilSeal(usetheforkoilsealdriver:57001-1219,the markedsideupward)
  RetainingRing
  DustSeal

• Measurethebothdiametersoftheforkspringendsand inserttheforkspringwiththesmalldiameterAfacing down.

• Pourtheforkoil(seeForkOilchange).
• Installthefrontfork(seeFrontForkInstallation).

Diagram of a coiled spring with labeled point A, no text or symbols present

FrontFork

InnerTubeInspection

• VisuallyinspecttheinnertubeA,repairanydamage.
• Nickorrustdamagecansometimesberepairedbyusing awet-stonetoremovesharpedgesorraisedareaswhich causesealdamage.
  ★ Ifthedamageisnotrepairable,replacetheinnertube. Sincedamagetotheinnertubedamagestheoilseal, replacetheoilsealwhenevertheinnertubeisrepaired orreplaced.
• Temporarily assemble the inner and outer tubes, and pump them back and forth manually to check for smooth operation.

NOTICE

Iftheinnertubeisbadlybentorcreased,replace it.Excessivebending,followedbysubsequent straightening,canweakentheinnertube.

GuideBushInspection

- VisuallyinspecttheguidebushesA, andreplacethemif necessary.

DustSeal/OilSealInspection

• InspectthedustsealAforanysignsofdeteriorationor damage.
  ★Replaceitifnecessary.
• Replacetheoilseal[B]withanewonewheneverithas beenremoved.

SpringTensionInspection

• Sinceaspringbecomesshorterasitweakens,checkits freelengthAtodetermineitcondition.
  ★ Ifthespringofeitherforklegisshorterthantheservice limit, itmustbereplaced. Ifthelengthofareplacement springandthatoftheremainingspringvarygreatly, the remainingspringshouldalsobereplacedinordertokeep theforklegsbalancedfromotorcyclestability.

ForkSpringFreeLength

Standard:455.7mm(KX65-A1)

470.7mm(KX65-A2)

497.1mm(KX65-A3\~)

ServiceLimit: 446.6mm(KX65-A1)

461.3mm(KX65-A2)

487.2mm(KX65-A3\~)

Simple line drawing of a vertical cylindrical object with a labeled point A (no text or symbols beyond the label)

Diagram of a coiled spring with labeled point A and reference number GM040118S1 C (no text or symbols on the diagram itself)

RearSuspension(Uni-Trak)

RearShockAbsorber

TherearsuspensionsystemofthismotorcycleisUni-trak. Itconsistsofarearshockabsorber,swingarm,tie-rodand rockerarm.

Tosuittovariousridingconditions,thespringpreloadof theshockabsorbercanbeadjustedorthespringcanbe replacedwithanoptionalone.

KX65-A3\~

Thedampingforce can be adjusted easily so changing oil viscosity unnecessary.

ReboundDampingForceAdjustment

• Toadjusttherebounddampingforce,turnthelower dampingadjusterApunchmark[B].
  ★Ifthedampingfeelstoosoftortoostiff,adjustit.

Seatedposition:adjustertunedfullyclockwiseA

ReboundDampingAdjusterSetting Standard:11/2turnsout

○Differtheindividuallyforshockabsorbersideofthepunch markposition[B].

graph TD
    A["(Counterclockwise) Softer"] --> B["1 1/2 STD"]
    C["(Clockwise) Harder"] --> D["3 Adjustable range"]
    B --> E["B"]
    D --> F["A"]
    style A fill:#f9f,stroke:#333
    style C fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style D fill:#ccf,stroke:#333

SpringPreloadAdjustment

- Remove:

Seat

SideCovers

RearFrameA

AirCleanerHousing[B]

- Usingthejackundertheframe,raisetherearwheeloff theground.

SpecialTool-Jack:57001-1238

- Using the hook wrenchesA, loosenthelocknut[B] on therearshockabsorber.

SpecialTool-HookWrench:57001-1101

Close-up of a mechanical assembly with labeled parts A and B, showing no readable text or symbols beyond labels.

11-16 SUSPENSION

RearSuspension(Uni-Trak)

- UsingthehookwrenchA,turntheadjustingnut[B]as required.Turningtheadjustingnutdownwardmarksthe springactionharderandupwardsofter.

SpecialTool-HookWrench:57001-1101

Close-up of a mechanical assembly with labeled parts A and B, showing hands adjusting components (no readable text or symbols)

SpringPreloadAdjustment

(AdjustingnutpositionAfromthecenter ofthemountinghole)

Standard:88.8mm(KX65-A1)

86.6mm(KX65-A2)

79.6mm(KX65-A3\~A6)

80.1mm(KX65A6F\~)

AdjustableRange:

82.8 \~ 94.8 mm (KX65-A1 \~ A2)

75.6 \~ 83.6 mm (KX65-A3 \~ A6)

76.1 \~ 84.1 mm (KX65A6F \~)

• Tightenthelocknutsecurely.
• Afteradjusting, movethespringupanddowntomake surethatthespringisseated.
  • Installthepartsremoved.
• Tightentherearframemountingbolts.

Torque-RearFrameMountingBolts:34N·m(3.5kgf·m25ft·lb)

RearShockAbsorberRemoval

- Remove:

Seat

SideCovers

RearFrame

AirCleanerHousing

- Usingthejackundertheframe,raisetherearwheeloff theground.

SpecialTool-Jack:57001-1238

- Removethetie-rodfrontmountingboltA.

NOTICE

When pulling out them mounting bolts, lift therear wheels slightly. Forcingortappingonabolt could damagethebolt, sleeve, and bearing

- RemovetherearshockabsorbermountingboltB].

RearSuspension(Uni-Trak)

- RemovetherearshockabsorberuppermountingboltA, andpullouttherearshockabsorber[B].

RearShockAbsorberInstallation

• Packtherockerarmneedlebearingswithgrease.
• Tightenthefollowing:

Torque-RearShockAbsorberMountingBolt(Upper):39 N·m(4.0kgf·m,29ft·lb)

RearShockAbsorberMountingNut(Lower):34 N·m(3.5kgf·m,25ft·lb)

Tie-rodMountingNut:59N·m(6.0kgf·m,43ft·lb)

RearFrameMountingBolts:34N·m(3.5kgf·m,25ft·lb)

SpringReplacement

Inadditiontothestandardspring,heavyandlightsprings areavailable.Ifthestandardspringisimproperforyour purpose,selectaproperoneaccordingtotherider'sweight orcourseconditions.

- Remove

SideCovers

Seat

RearFrame

AirCleanerHousing

• Removetherearshockabsorber.
• Cleanethreadedportionontheupperoftherearshock absorber.
• Holdtheloweroftherearshockabsorberwithavise.
• Using the hookwrenches[C], loosenthelocknut[B] and turnthead adjusting nutA all wayup.

SpecialTool- HookWrench:57001-1101

11-18 SUSPENSION

RearSuspension(Uni-Trak)

• Removetherearshockabsorberfromthevise.
• RemovethestopperringA.
• Removethespringseat[B]fromtheshockabsorberand liftoffthespring[C].

• Installthespringguide.
- Adjust the spring preload (see Spring Preload Adjustment).
• Installtherearshockabsorber.
• Installthepartsremoved.

SpringTension

Sinceaspringbecomesshorterasitweakens,checkits freelengthAtodetermineitscondition.

★ Ifthespringisshorterthantheservicelimit, it must be replaced.

RearShockAbsorberSpringFreeLength

Standard:206.1mm(KX65-A1\~A2)

211.1mm(KX65-A3\~)

ServiceLimit:202.0mm(KX65-A1\~A2)

206.9mm(KX65-A3\~)

Close-up of a black helical spring with diameter labeled 'A' (no text or symbols on the spring itself)

RearShockAbsorbe rScrapping

WARNING

Sincethereserv oirtankoftherearshockabsorber containsnitrogengas, donotincineratethereserv-voirtankwithoutfirstreleasingthegasoritmay explode.

• Removetheshockabsorber(seeRearShockAbsorber Removal).
• RemovethevalvecapAandreleasethenitrogengas completelyfromthegasreservoir.
• Removethevalve.

WARNING

Pressurizedgascancauseinjury.Donotpointthe valvetowardyourfaceorbody.

Technical line drawing of a mechanical assembly with cylindrical components and a labeled component (no text or symbols present)

Swingarm

SwingarmRemoval

- Placethejackundertheframesothattherearwheelis offtheground.

SpecialTool-Jack:57001-1238

• Removetherearwheel(seeWheels/Tireschapter).
• RemovethebrakepedalA.
• Removethetie-rodrearmountingbolt[B].

NOTICE

When pulling out them mounting bolts, lift therear wheels slightly. Forcingortappingonabolt could damagethebolt, sleeve, and bearing.

• Pullouttheswingarmpivotshaft[C], andremovethe swingarm[D].
• Separatethechainguideandchainslipperfromthe swingarm.

SwingarmInstallation

• Applyplentyofgreasetotheinsideoftheneedlebearings, sleeves, and oilsealscaps.
• Tightenthefollowing:

Torque-SwingarmPivotShaftNut:69N·m(7.0kgf·m,51ft·lb)

Tie-rodMountingNut:59N·m(6.0kgf·m,43ft·lb)

- RefertotheWheels/Tires, FinalDrive, and Brakeschapters for wheel installing.

SwingarmBearingRemoval

- Remove:

Swingarm

DustSealsA

OilSeals[B]

Sleeves[C]

- Removetheneedlebearings[D]usingthebearingremover.

SpecialTool-OilSeal&BearingRemover:57001-1058

Swingarm

SwingarmBearingInstallation

• Replacetheneedlebearings, dustsealsandoilsealswith newones.
• Applyplentyofgreasetothedustseals, oilsealsand needlebearings.

NOTE

○Installtheneedlebearingssothatthemanufacturer's marksfaceout.

SpecialTool-BearingDriverSet:57001-1129

• InstalltheneedlebearingsAdustseals[B]andoilseals[C]positionasshown.
  ○ Theinstallationprocedureisthesameasthecounter side.

Tie-rod,RockerArm

Tie-rodRemoval

- Usingthejackundertheframe,raisetherearwheeloff theground.

SpecialTool-Jack:57001-1238

- Removethetie-rodfrontmountingboltA.

NOTICE

When pulling out them mounting bolts, lift therear wheels slightly. Forcingortappingonabolt could damagethebolt, sleeve, and bearing.

- Removethetie-rodrearmountingbolt[B], andthentake outthetie-rods[C].

Tie-rodInstallation

• Applyplentyofgreasetotheinsideoftheneedlebearings andoilseals.
• Tightenthetie-rodfrontandrearmountingnuts.

Torque-Tie-rodMountingNuts:59N·m(6.0kgf·m,43ft·lb)

RockerArmRemoval

- Usingthejackundertheframe,raisetherearwheeloff theground.

SpecialTool-Jack:57001-1238

- RemovethechainAandthelowerchainguideroller[B].

- Removethetie-rodfrontmountingboltA.

NOTICE

When pulling out them mounting bolts, lift therear wheels slightly. Forcingortappingon bolt could damage the bolt, sleeve, and bearing.

• Removetherearshockabsorberlowermountingbolt[B].
• Removetherockerarmpivotshaft[C].
• Removetherockerarm[D].

Mechanical assembly diagram showing a chain link and labeled components A and B (no text or symbols beyond labels)

11-22 SUSPENSION

Tie-rod,RockerArm

RockerArmInstallation

• Applyplentyofgreasetotheinsideoftherockerarm holes, needlebearings, oilsealsandgreasesealsoutsideofthesleeve.
• InstalltheneedlebearingA,greaseseals[B]andoil seals[C]positionasshown.
• Tightenthefollowing:

Torque-RockerArmPivotNut:83N·m(8.5kgf·m,61ft·lb)

RearShockAbsorberMountingNut(Lower):34 N·m(3.5kgf·m,25ft·lb)

Tie-rodMountingNuts:59N·m(6.0kgf·m,43ft·lb)

SwingarmPivotShaftNut:69N·m(7.0kgf·m,51ft·lb)

NeedleBearingInspection

★ Ifthereisanydoubtastotheconditionofeitherneedle bearing,replacethebearingandsleeveasaset.

Uni-TrakMaintenance

Checktheuni-trakcomponentpartsforwearperiodically, orwheneverexcessiveplayissuspected.

- Usingthejackundertheframe,raisetherearwheeloff theground.

SpecialTool-Jack:57001-1238

• PushandpullontheswingarmA, upanddown, tocheck forwear.
  ★Asmallamountofplayontheswingarmisnormalandno correctiveactionisneeded.However,ifexcessiveplayis felt,removetheuni-trakpartsfromtheframeandcheck forwear.

RockerArmSleeveWearInspection

• PulloutthesleevesAoftherockerarm,andmeasure theoutsidediameterofthesleeve.
  ★ Ifthesleeveiswornpasttheservicelimit,replacethe sleeve.

SleeveOutsideDiameter

Standard: 17.989\~18.000mm

ServiceLimit: 17.96mm

Close-up of a hand adjusting a bicycle wheel rim with labeled components (no readable text or symbols)

Mechanical assembly with a metallic valve and multiple small components (no visible text or symbols)

RockerArmMountingBoltBendInspection

Abentboltcausesvibration,poorhandling,andinstability.

• Tomeasuretheboltrunout,removethebolt,placeit inVblock,andsetadialgaugetotheboltatapoint halfwaybetweenheblock.TurnAthebolttomeasure therunout.Theamountofdialvariationistheamountof runout.
  ★ Ifrunoutexceedstheservicelimit, replacethebolt.

BoltRunout

Standard: Under0.1mm

ServiceLimit: 0.2mm

Steering

TableofContents

Exploded View 12-2

Specifications 12-3

Steering 12-4

Steering Inspection 12-4

Steering Adjustment.... 12-4

SteeringStem,StemBearingRemoval....12-5

SteeringStem,StemBearingInstallation....12-6

Steering Maintenance.... 12-8

Stem Bearing Lubrication.... 12-8

StemBearingWear, DamageInspection....12-8

Stem Warp Inspection.... 12-8

Handlebar 12-9

Handlebar Removal 12-9

Handlebar Installation 12-9

Clutch Lever Installation.... 12-9

1. HandlebarClamp
2. Handlebar
3. SteeringStemHeadNut
4. SteeringStemHeadBracket
5. SteeringStemNut
   6.TaperedRollerBearing
   7.HeadPipe
   8.TaperedRollerBearing
6. SteeringStem

T3:2.9N·m(0.30kgf·m,26in·lb)

T4:25N·m(2.5kgf·m,18ft·lb)

T5:29N·m(3.0kgf·m,22ft·lb)

T6:8.8N·m(0.90kgf·m,78in·lb)

AD:Applyadhesivecement.

G:Applygrease.

Specifications

SpecialTools-SteeringStemBearingDriver:57001-137

HeadPipeOuterRacePressShaft:57001-1075

SteeringStemBearingDriverAdapter:57001-1092

SteeringStemNutWrench:57001-1100

HeadPipeOuterRaceDriver:57001-1106

HeadPipeOuterRaceRemover:57001-1107

Jack:57001-1238

Steering

SteeringInspection

• Usingthejack,raisethefrontwheelofftheground.
  SpecialTool-Jack:57001-1238
• Withthefrontwheelpointingstraightahead, alternately nudgeeachendofthehandlebar. Thefrontwheelshould swingfullyleftandrightfromtheforceofgravityuntilthe forkhitsthestop.
  ★ If the steering binds or catches before the stop, check the routing of the cables, hoses, and harnesses.
  ★ Ifthesteeringfeelstight, adjustorlubricatethesteering.
• Feelforsteeringloosenessbypushingandpullingthe forks.
  ★ Ifyoufeellooseness,adjustthesteering.

SteeringAdjustment

• Removethenumberplate.
• Usingthejack,raisethefrontwheelofftheground.
  SpecialTool-Jack:57001-1238
• Removethehandlebar.
• LoosenthefrontforkclampboltsAandsteeringstem headnut[B].

Close-up of hands adjusting a bicycle wheel rim and tire assembly (no visible text or symbols)

Close-up of mechanical components with no visible text or symbols

Close-up of a mechanical component with labeled point B (no readable text or symbols)

• TurnthesteeringstemnutAwiththesteeringstemnut wrench[B]toobtaintheproperadjustment.
  ★ Ifthesteeringistootight, loosenthesteeringstemnuta fractionofaturn; ifthesteeringistooloose, tightenthe nutafractionofaturn.
  SpecialTool-SteeringStemNutWrench:57001-1100

NOTE

○Turnthesteeringstemnut1/8turnatatimemaximum.

- Tightenthefollowing:

Torque-Steering Stem Head Nut: 44N·m (4.5kgf·m, 33ft·lb)

Front Fork Clamp Bolts (Lower): 29 N·m (3.0 kgf·m,22ft·lb)

Steering

SteeringStem, StemBearingRemoval

- Remove:

FrontWheel(seeWheels/Tireschapter) BrakeHoseClamp(seeBrakeSystemchapter) CaliperMountingBolts(seeBrakeSystemchapter) MasterCylinderClamp(seeBrakeSystemchapter) FrontFender Handlebar(seeHandlebarRemoval) FrontFork(seeSuspensionchapter)

• Removethesteeringstemheadnutandwasher.
• Removethesteeringstemhead.
• PushinguponthestembaseA,andremovethesteering stemnut[B],withthesteeringstemnutwrench[C],then removethesteeringstem[D].
  SpecialTool-SteeringStemNutWrench:57001-1100

- Takeofftheupperstembearinginnerrace(taperedroller bearing)A.

- Driveoutthebearingouterracesfromtheheadpipe. ○Removetheouterracespressedintotheheadpipe,using theheadpipeouterraceremoverA,andhammerthe headpipeouterraceremovertodriveitout.

SpecialTool-HeadPipeOuterRaceRemover:57001 -1107

NOTE

○ Ifeithersteeringstem bearingisdamaged,itisrecommendedthatboththeupperandlowerbearing(includingouterraces)shouldbereplacedwithnewones.

- Removethelowerstembearinginnerrace(taperedroller bearing)Awithitsgreasesealfromthestemusingsuitabletools.

Steering

SteeringStem, StemBearingInstallation

• Replacethebearingouterracewithnewones.
  ○Applygreasetotheouterraces, and drivetheminto the headpipe using the pressshaftA and the drivers[B].

SpecialTools-HeadPipeOuterRacePressShaft:57001

-1075

HeadPipeOuterRaceDriver:57001-1106

• Replacethelowerinnerraceswithnewones.
  ○Applygreasetothelowerinnerrace, and drive it onto the stem using the steering stem bearing driverA and adapter[B].

SpecialTools-SteeringStemBearingDriver:57001-137

SteeringStemBearingDriverAdapter: 57001-1092

• Applygreasetotheupperinnerrace, and installitinthe headpipe.
• Installthestemthroughsteeringtheheadpipeandupperbearing,andhand-tightenthesteeringstemnutwhile pushinguponthestembase.
• Installthestemheadandwasher, andtightenthestem headnutlightly.
• Settlethebearinginplaceasfollows;
  ○ Tightenthesteeringstemnutto39N·m(4.0kgf·m,29ft·lb)oftorque.(Totightenthesteeringstemnuttothe specifiedtorque,hookthewrenchAonthesteeringstem nut,andpullthewrenchattheholeby22.2kgforce[B] inthedirectionshown.)

SpecialTooI - SteeringSt emNutWrench:57001-1100

○Checkthatthereisnoplayandthesteeringstemturns smoothlywithouttrattles.Ifnot,thesteeringstembearings maybedamaged.
○Againbackoutthesteeringstemnutafractionofaturn untilturnslightly.
Turnthesteeringstemnutlightlyclockwiseuntilitjust becomeshardtoturn.Donotovertighten,orthesteering willbetootight.

Torque- SteeringStemNut:2.9N·m(0.3kgf·m,26in·lb)

• Installthefrontfork(seetheSuspensionchapter).

NOTE

○Tightentheforkupperclampboltsfirst,nextthestem headnut,lasttheforklowerclampbolt.

Steering

Torque-SteeringStemHeadNut:44N·m(4.5kgf·m,33ft·lb)

FrontForkClampBolt:

Upper:20N·m(2.0kgf·m,15ft·lb)

Lower:29N·m(3.0kgf·m,22ft·lb)

- Installthepartsremoved(seetheappropriatechapter).

WARNING

Donotimpedethehandlebarturningbyroutingthe cables,wiresandhosesimproperly(seetheGeneralInformationchapter).

- CheckandAdjust:

Steering

FrontBrake

ClutchCable

ThrottleCable

12-8STEERING

SteeringMaintenance

StemBearingLubrication

• Removethesteeringstem(seeSteeringStemRemoval).
• Usingahighflash-pointsolvent,washtheupperand lowertaperedrollersinthecages,andwipetheupper andlowerouterraces,whicharepress-fittedintothe frameheadpipe,cleanoffgreaseanddirt.
• Visuallychecktheouterracesandtherollers.
  ★Replacethebearingassembliesiftheyshowwearor damage.
• PacktheupperandlowertaperedrollerbearingsAin thecageswithgrease,andapplyalightcoatofgreaseto theupperandlowerouterraces.
• Installthesteeringstem, and adjust thesteering (see SteeringStem, StemBearing Installation, Steering Adjustment).

StemBearingWear, DamageInspection

• Usingahighflash-pointsolvent,washtheupperand lowertaperedrollersinthecages,andwipetheupper andlowerouterraces,whicharepress-fittedintothe frameheadpipe,cleanoffgreaseanddirt.
• Visuallychecktheouterraseandtherollers.
  ★Replacethebearingassemblyifitshowdamage.

StemWarpInspection

• Whenever the steering stem is removed, or the steering cannot be adjusted for smooth action, check the steering stem for straightness.
  ★ If thesteeringstemshaft is bent A, replace thesteering stem.

Mechanical component with labeled parts (A and a small circular feature), no readable text or symbols present.

Technical line drawing of a mechanical assembly with labeled component A (no text or symbols beyond label)

Handlebar

HandlebarRemoval

- Remove:

EngineStopButtonA

ClutchHolder[B]

ThrottleGripAssembly[C]

FrontMasterCylinder[D]

HandlebarHolders[E]

Handlebar[F]

HandlebarInstallation

• Applyadhesivecementtotheinsideofthelefthandlebar gripA.

• Installthefrontmastercylinder(seeFrontMasterCylinder InstallationintheBrakeschapter).

• Mountthehandlebarclamps[B]sothathearrows[C]on theclamppointatthefrontA.

• Alignthepunchmark[D]onthehandlebartothemating surfaceofeachclampsofhandlebar.
• Tightenthehandlebarclampbolts.

Torque-HandlebarClampBolts:25N·m(2.5kgf·m,18 ft·lb)

○Tightentheclampbolts,frontfirstandthentherear. If thehandlebarclampiscorrectlyinstalled,therewillbeno gapatthefrontandagap[E]attherearaftertightening.

ClutchLeverInstallation

- InstalltheclutchleversothatthematingsurfaceAofthe clutchleverclampisalignedwiththepunchmark[B].

Torque-ClutchLeverClampBolts:8.8N·m(0.90kgf·m,78in·lb)

ElectricalSystem

TableofContents

Wiring Diagram.... 13-2

Exploded View.... 13-3

Specifications 13-4

Precautions.... 13-5

Electrical Wiring 13-6

Wiring Inspection 13-6

Ignition Timing 13-7

Ignition Timing Adjustment.... 13-7

Flywheel Magneto 13-8

Flywheel Magneto Removal.... 13-8

Flywheel Magneto Installation.... 13-8

Crankshaft Sensor Air Gap Inspection (KX65A6F \~) 13-9

Flywheel Magneto Inspection 13-9

Ignition System.... 13-11

Crankshaft Sensor Installation (KX65A6F \~) 13-11

Crankshaft Sensor Air Gap Adjustment (KX65A6F \~) 13-11

Crankshaft Sensor Inspection (KX65A6F \~) 13-11

Crankshaft Sensor Peak Voltage Inspection (KX65A6F \~) 13-12

Ignition Coil Removal 13-12

Ignition Coil Installation 13-12

Ignition Coil Inspection.... 13-12

Spark Plug Cleaning and Inspection.... 13-14

Spark Plug Gap Inspection 13-14

CDI Unit Removal 13-14

CDI Unit Inspection 13-14

13-2 ELECTRICAL SYSTEM

WiringDiagram

GP07016BW2 C

KX65A6F\~

graph TD
    A["Magneto"] --> B["Crankshaft Sensor"]
    B --> C["CDI Unit"]
    C --> D["Ignition Coil"]
    D --> E["Engine Stop Button"]
    E --> F["Spark Plug Cap"]
    F --> G["Spark Plug"]
    G --> H["Ground"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#ffc,stroke:#333
    style F fill:#cff,stroke:#333
    style G fill:#ffc,stroke:#333
    style H fill:#cfc,stroke:#333
    subgraph Color Code
        I["BK Black"]
        J["G Green"]
        K["O Orange"]
        L["R Red"]
        M["W White"]
        N["Y Yellow"]
    end

ExplodedView

1.MagnetoCover
2.MagnetoFlywheel
3. Stator
4.CDIUnit
5.IgnitionCoil
6.SparkPlugCap
7.SparkPlug
8. EngineStopButton
9.KX65-A1\~A6
T1:29N·m(3.0kgf·m,21ft·lb)
T2:4.9N·m(0.50kgf·m,43in·lb)
T3:25N·m(2.6kgf·m,19ft·lb)
T4:8.8N·m(0.90kgf·m,78in·lb)
SS:Applysiliconesealant.

GP022958W4 C

Specifications

Item	Standard
MagnetoStatorcoilresistanceinthetext
IgnitionSystemIgnitionTiming:IgnitionCoil:3NeedleArcingDistance7mmormorePrimary Winding ResistanceSecondaryWindingResistance3.1kΩ ±15%SparkPlug:TypeGap0.5~ 0.6mmCDI.unit:inthetext	20.5°BTDC@6000r/min(rpm)20.5°BTDC@7100r/min(rpm)(KX65A6F~)0.31 Ω ±15% (at 20°C)(at20°C)NGKBR10EGNGKB10EG(KX65-A1~ A6(US))

SpecialTools-FlywheelPuller:57001-252

Flywheel&PulleyHolder:57001-1343

HandTeste:57001-1394

PeakVoltageAdapter:57001-1415

LiquidGasket, TB1211:56019-120

US:UnitedStatesModel

Precautions

Thereare numbers of important precaution that are must always servicing electrical systems. Learn and observe all the rules below.

○Theelectricalpartsshouldneverbestrucksharply,as withahammer,orallowedtofallonahardsurface.Such ashocktothepartscandamagethem.
○Troublesmayinvolveoneorinsomecasesallitems. Neverreplaceadefectivepartwithoutdeterminingwhat CAUSEDthefailure.Ifthefailurewascausedbysome otheritemoritems,theytoomustberepairedorreplaced, orthenewreplacementwillsoonfailagain.
○Makesureallconnectorsinthecircuitarecleanandtight, andexaminewiresforsignsofburning, fraying, etc. Poor wiresandbadconnectionswillaffectelectricalsystemoperation.
○Measurecoilandwindingresistancewhenthepartiscold (atroomtemperature).

SafetyInstructions

WARNING

Theignitionsystemproducesextremelyhighvoltage.Donottouchthesparkplug,ignitioncoilorignitioncoilleadwhiletheengineisrunning,oryou couldreceiveasevereelectricalshock.

13-6 ELECTRICAL SYSTEM

Electrical Wiring

WiringInspection

• Visuallyinspectthewiringforsignsofburning,fraying, etc.
  ★ Ifanywiringispoor, replacethedamagedwiring.
• PulleachconnectorAapartandinspectitforcorrosion, dirt, and damage.
  ★ Iftheconnectoriscorrodedordirty, cleanitcarefully. Ifit isdamaged, replace it.
• Checkthewiringforcontinuity.
  ○Usethewiringdiagramtofindtheendsoftheleadwhich issuspectedofbeingaproblem.
  ○Connectanohmmeterbetweentheendsoftheleads.
  ○Setthemetertothe×1Ω range, andleadthemeter.
  ★ Ifthemeterdoesnotread0Ω theleadisdefective. Re- placetheleadorthewiringharnessifnecessary.

Pure electrical circuit lines without any symbols

IgnitionTiming

IgnitionTimingAdjustment

• Removethemagnetocover.
• ChecktoseeifthecentermarkofthethreemarksAon themagnetostatorplateisalignedwiththemark[B]on thecrankcase.
  ★Ifthemarksarenotaligned,loosenthemagnetostator platemountingscrews[C]andturnthestator[D].
• Tightenthestatorplatemountingscrewssecurely.

Torque-StatorPlateMountingScrews:4.9N·m(0.50 kgf·m,43in·lb)

• Installthemagnetocover.
Torque-MagnetoCoverBolts:8.8N·m(0.90kgf·m,78in·lb)

Theignitiontimingcanbeadjustedfordifferentpower bandtosuittorider'spreferenceability.

• Removethemagnetocover.
• Loosenthestatorplatemountingscrews.
• Adjustthetimingbyshiftingthestatorpositionwithinthe threelinesA.

Technical line drawing of a mechanical assembly with bolted components and labeled section A (no readable text or symbols beyond labels)

NOTE

○ Forbestengineperformance,itisveryimportanttoadjusttheignitiontimingwithintheadjustablerangejust explained.

ACrankshaftRotation
[B]Statorplateofmovement
[C]Advance
[D]Retard

• Tightenthestatorplatemountingscrews securely (see IgnitingTimingAdjustment).
  • Installthemagnetocover.
• Testridethemotorcycleandreadjusttheignitiontimingif necessary.

FlywheelMagneto

FlywheelMagnetoRemoval

• Removethemagnetocover.

• Holdtheflywheelsteady, withtheflywheel&pulleyholder A, andremovetheflywheelnut[B].
  SpecialTool-Flywheel&PulleyHolder:57001-1343

• ScrewtheflywheelpullerAintotheflywheelbyturning itcounterclockwise(left-handthread).

• Removetheflywheelfromthecrankshaftbyturninginthe pullercenterboltandtappingtheheadoftheboltlightly withahammer,whileholdingthepullerbodysteady. Thereisawoodruffkeyinthecrankshafttaperedportion.
  SpecialTool-FlywheelPuller:57001-252

NOTICE

Neverstrikethegrabbarortheflywheelitself. Strikethebarcanbondit.Iftheflywheelisstrike, themagnetsmaylosetheirmagnetism.

• Unscrewthemounti ngscrewsA,andremovethestator plate[B]andthewiringgrommet[C].
• Removetheband.
• Disconnectt hestatorleadconnectorsfromtheharness.

FlywheelMagnetolnstallation

• Installthestatorplate.
- Applysiliconesealantaroundthestatorwiringgrommet A, andsetitinthenotch[B] in the left crank case half securely, and routethe leads according to the Cable, Wire and Hose Routing section in the General Information chapter.

Torque-StatorPlateMountingScrews:4.9N·m(0.50 kgf·m,43in·lb)

Sealant-LiquidGasket, TB1211:56019-120

FlywheelMagneto

• Usingahighflash-pointsolvent,cleanoffanyoilordirt thatmaybeonthecrankshafttaperAorinthehole[B]intheflywheel.Drythemwithacleancloth.
• FitthewoodruffkeyAsecurelyintheslotinthecrank-shaftbeforeinstallingthestatorplate.
• Holdingtheflywheelsteady, withtheflywheelholderA, andtightentheflywheelnut[B].

SpecialTool-Flywheel&PulleyHolder:57001-1343

Torque-FlywheelNut:29N·m(3.0kgf·m,21ft·lb) MagnetoCoverBolts:8.8N·m(0.90kgf·m,78in·lb)

CrankshaftSensorAirGapInspection(KX65A6F \~)

• Removethemagnetocover.
• MeasurethecrankshaftsensorairgapA.

CrankshaftSensorAirGap

0.5±0.1mm(0.020±0.004in.)

★ Ifthegapisincorrect, reinstallthecrankshaftsensorso thatthegaphascorrectclearance.

FlywheelMagnetoInspection

- Therearethreetypesofmagnetoproblems:short,open (wireburnedout),orlossinflywheelmagnetism.Ashort oropeninoneofthecoilwireswillresultineitheralow output,ornooutputatall.Alossinflywheelmagnetism, whichmaybecausedbydroppingorhittingtheflywheel byleavingitnearanelectromagneticfield,orjustbyaging,willresultinlowoutput.

13-10 ELECTRICAL SYSTEM

FlywheelMagneto

• Tocheckthestatorcoilresistanceasfollows.
  ○Connectthehandtestertotheterminalsoftheharness connectorAasshowninthetable2.
  ○Notethereadings.

Table2StatorCoilResistance

TesterRange	Connections		Reading
	Tester(+)Tester(+)
×1Ω	Black/Red Lead	Black/White Lead	214Ω ±20%

KX65A6F\~:

TesterRange	Connections		Reading
	Tester(+)Tester(-)o
×100Ω	Black/White Lead	Black/Red Lead	288~432Ω

★ Ifthereismoreresistancehanshowninthe table,orno handtesterreading(infinity)thestatorhasanopenlead andmustbereplaced.Muchlessthanthisresistance meansthestatorisshorted,andmu stbereplaced.
- Using the highest resistance range of the hand tester, measure the resistance between each leads and chassis ground.
★Anyhandtesterreadinglessthaninfinity(∞)indicatesa short, necessitatingstatorreplacement.
★ Ifthestatorcoilshave normalresistance, but the voltage check showed them magnetotobedefective; then therotor magnet shave probably weakened, and therotormust be replaced.

SpecialTool-HandTester:57001-1394

IgnitionSystem

SafetyInstructions

WARNING

Theignitionsystemproducesextremelyhighvoltage.Donottouchthesparkplug,ignitioncoilorignitioncoilleadwhiletheengineisrunning,oryou couldreceiveasevereelectricalshock.

CrankshaftSensorInstallation(KX65A6F \~)

- Installthecrankshaftsensorsothattheairgap(clearance betweentheflywheelandthecrankshaftsensorcore)has correctclearance(seeFlywheelMagnetoInstallation).

CrankshaftSensorAirGapAdjustment(KX65A6F \~)

• Removethemagnetocover.
• Loosenthecrankshaft sensorscrewsA.
• Inserta0.5mmthicknessgauge[B]betweenthecrank-shaftsensorcoreandthetimingplate.
• Whilepressingthecrankshaftsensortowardthemagneto flywheel, tightenthecoilscrewsandremovethethickness gauge.

- Checktheairgap(SeeFlywheelMagnetoInstallation). Crankshaft Sensor Air Gap: 0.4 \~ 0.6 mm (0.016 \~ 0.024 in.)

★ If the air gap is not within the specified range, read just the gap.

CrankshaftSensorInspection(KX65A6F \~)

• Removethefollowing MagnetoLeadConnectorA
• Setthehandtester[B]tothe×100Ω rangeandconnect ittothemagnetoleadconnector(crankshaftsensorlead) connector.

SpecialTool-HandTester:57001-1394

★ Ifthereismoreresistancethanthespecifiedvalue,the coilhasanopenleadandmustbereplaced.Muchless thanthisresistancemeansthecoilisshorted,andmust bereplaced.

CrankshaftSensorResistance

W/G \~ W/R Leads: 396 \~ 594 Ω (× 100 Ω)

• Using the highest resistance range of the hand tester, measure the resistance between the crankshaft sensor leads and chassis ground.
  ★Anyhandtesterreadinglessthaninfinity(∞)indicatesa short, necessitatingreplacementofthestator.

IgnitionSystem

CrankshaftSensorPeakVoltageInspection (KX65A6F \~)

• Disconnectthemagnetoleadconnector[C].
• Setthehandtester[B]tothe×25VDCrange,andconnectitacommerciallyavailablePeakvoltageadapterAasshowninthediagram.
• ConnecttheblackleadoftheadaptertoWhite/Green leadandredleadtoWhite/Redleadofthemagnetolead adapter.
• Kickingtheprimarykick,turntheengine4\~ 5seconds withthetransmissiongearinneutraltomeasurethe crankshaftsensorpeakvoltage.
• Repeatthemeasurement5ormoretimes.

CrankshaftSensorPeakVoltage

Standard:

4.0Vormore

SpecialToos-HandTester:57001-1394

PeakVoltageAdapter:57001-1415

Type:KEK-54-9-B

WARNING

Electricalequipmentcancauseseriouselectrical shock.Toavo idbeingshocked,donottouchthe metalportionoftheprobewhenmeasuringvoltage.

★ If the voltage is less than the specified, replace the pickup coil.

IgnitionCoilRemoval

• Remove:
  Seat
  SideCovers
  Shroud
  FuelTank
• DisconnecttheignitioncoilprimaryleadA.
• Pulltheplugcapoffthesparkplug.
• Unscrewthemountingbolts[B], andremovetheignition coil[C].

IgnitionCoilInstallation

• Installationisthereverseofremoval.
  Torque-IgnitionCoilMountingBolts:8.8N·m(0.90kgf·m, 78in·lb)

IgnitionCoilInspection

Measuring arcing distance

Thermostaccuratetestfordeterminingtheconditionof theignitioncoilismadebymeasuringarcingdistanceusing thecoiltesterforthe3-needlemethod.

• Removetheignitioncoil.
• Connecttheignitioncoil(withthesparkplugcapleftinstalledonthesparkpluglead)Atothetester[B],and measurethearcingdistance.

VIEWED FROM FRONT

GP100501S1 C

IgnitionSystem

WARNING

Toavoidextremelyhighvoltageshocks, donot touchthecoilorlead.

★ Ifthedistancereadingislessthanthespecifiedvalue,the ignitioncoilorsparkplugcapsdefective.

3 Needle Arcing Distance Standard: 7 mmormore

• Todeterminewhichpartisdefective,measurethearcing distanceagainwiththesparkplugcapremovedfromthe ignitioncoillead.
  ★ Ifthearcingdistanceissubnormalasbefore,thetrouble iswiththeignitioncoilitself. Ifthearcingdistanceisnow normal,thetroubleiswiththesparkplugcap. C:KX65A6F\~

MeasuringCoilResistance

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 underhighvoltage.

- Removetheignitioncoil.

- Measure the primary winding resistance A.

○Connectanohmmeterbetweenthecoilterminals.

○Setthemetertothe×1Ω range,andreadthemeter. KX65A6F[C]

• Measurethesecondarywindingresistance[B].
  ○Pullthesparkplugcapoffthelead.
• Connectanohmmeterbetweenthesparkplugleadand thegroundleadterminal.
• Setthemetertothe×1kΩ range,andreadthemeter.
  ★ Ifthemeterdoesnotreadasspecified, replacethecoil.
  ★ Ifthemeterreadsasspecified, 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, testreplacethe coil with one known tobegood.

IgnitionCoilWindingResistance

Primary Windings: 0.26 \~ 0.36 Ω (× 1 Ω)

Secondary Windings: 2.64 \~ 3.57 Ω (× 1 kΩ)

KX65A6F\~

PrimaryWindings: 0.36 \~ 0.48 Ω (× 1 Ω)

Secondary Windings: 5.4 \~ 7.4 Ω (× 1 kΩ)

• Checkthesparkplugleadforvisibledamage.
  ★Ifthesparkplugleadisdamaged,replacethecoil.

IgnitionSystem

SparkPlugCleaningandInspection

• Removethesparkplug, and visually inspectit.
• Cleanthesparkplug, preferablyinasandblastingdevice, andthencleanoffanyabrasiveparticles. Theplugmay also be cleaned using a high flash-points solvent and a wire brush or others suitable tool.

★ Ifthesparkplugelectrodesarecorrodedordamaged, oriftheinsulatoriscracked, replacetheplug. Usethe standardsparkplug.

Torque-SparkPlug:26N·m(2.6kgf·m,19ft·lb)

SparkPlugGapInspection

• MeasurethegapAwithawire-typethicknessgauge.
  ★ Ifthegapisincorrect, carefullybendthesideelectrode [B]withasuitabletooltoobtainthecorrectgap.

SparkPlugGap

Standard: 0.5\~0.6mm

CDIUnitRemoval

• Turnthehandlebartotheright. (KX65-A1\~A6)
• DisconnecttheharnessconnectorA.
• Unscrewthemountingbolt[B]andremovetheCDIUnit [C].

KX65A6F\~:

• DisconnecttheharnessconnectorA.
• RemovetheCDIUnitmountingbolts[B]andremovethe CDIUnit[C].

Torque-CDIUnitMountingBolts:8.8N·m(0.90kgf·m,78in·lb)

CDIUnitInspection

NOTICE

When inspecting the CDIUnit observ the following to avoid damage to the CDIUnit.

DonotdisconnecttheCDIUnitwhiletheengineis running.

ThismaydamagetheCDIUnit.

IgnitionSystem

IgnitionCoilPrimaryPeakVoltageCheck

- Remove:

Shrouds

SideCovers

Seat

FuelTank

• DisconnectthesparkplugcapfromthesparkplugA.
• Connectthenewsparkplug[B]tothesparkplugcap, thengroundittotheengine.

NOTE

○ Measure the voltage with each lead connected correctly. The correct value may not be obtained if disconnected.
○ Maintainthecorrectvalueofcompressionpressurefor thecylinder.(Besuretomeasurethevoltagewiththe sparkpluginstalledtothecylinderhead.)

- ConnectthepeakvoltageadapterAbetweenheterminalofprimarylead(orange)andgroundconnectionofthe leadoftheignitioncoil[B].

SpecialTool-PeakVoltageAdapter:57001-1415

Type: KEK-54-9-B

HandTester:57001-1394

Connection:

TesterPositive→ GroundLead[C]

TesterNegative→OrangeLead[D]

• Shiftthegeartotheneutralposition, thenpushtheengine stopbutton.
• Crank the engine by kicking the pedal several times to measure the peak voltage of the primary ignition coil.

PeakVoltage: DC115Vorabove

WARNING

Electrical equipment can cause serious electrical shock. To avoid being shocked, do not touch the metal portion of the probewhen measuring voltage.

★Ifthevoltageislessthanthespecifiedvalue,seethenext page.

Troubleshooting

graph TD
    A["Faulty ignition (Malfunctioned engine)"] --> B["Wiring and connect portion of the ignition system inspection"]
    B -->|Good| C["Spark plug inspection"]
    B -->|No good| D["Repair"]
    C -->|Good| E["Spark plug cap inspection"]
    C -->|No good| F["Replace"]
    E -->|Good| G["Ignition coil primary peak voltage inspection"]
    E -->|No good| H["Replace"]
    G -->|Good| I["Voltage is specified but faulty ignition"]
    G -->|No good. Voltage is none or almost none.| J["Defective ignition coil"]
    I --> K["Replace"]
    J --> L["Inspect"]
    L --> M["1. Adapter connection is incorrect or adapter is directive."]
    L --> N["2. Engine stop switch (button)"]
    L --> O["3. Crankshaft sensor peak voltage (KX65A6F)"]
    L --> P["4. Exciter coil peak voltage"]
    Q["Inspect"] --> R["1. Speed of cranking engine is slow. (Increase force of kicking engine.)"]
    Q --> S["2. Lower resistance in the tester. (Use KAWASAKI Hand Tester)"]
    Q --> T["3. Lacking of sampling (Sampling few times)"]
    Q --> U["4. Crankshaft sensor peak voltage (KX65A6F)"]
    Q --> V["5. Exciter coil peak voltage"]
    R --> W["C.D.I Unit is defective"]
    S --> W
    T --> W
    U --> W
    V --> W
    W --> X["Replace the malfunctioned parts or inspect in proper way"]
    X --> Y["No good"]
    Y --> Z["Replace the malfunctioned parts or inspect in proper way"]

IgnitionSystem

Exciter(Stator)CoilPeakVoltageCheck

• DisconnecttheconnectoroftheharnessfromtheCDI Unit.
• Tocheckthepeakvoltage,dothefollowingprocedures.

NOTE

○ Measure 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 (Besuretomeasure the voltage with the spark plugin installed to the cylinder head).

○ConnectthepeakvoltageadapterAofthetestertothe terminalsoftheharnessconnector[B].

SpecialTool-PeakVoltageAdapter:57001-1415

Type:KEK-54-9-B

HandTester:57001-1394

Close-up of an analog multimeter with labeled points A and B, showing measurement scales and wiring (no readable text beyond labels)

Connection:

AdapterPositive→ Black/RedLead

AdapterNegative→ Black/WhiteLead

○Cranktheenginebykick ingthepedalseveraltimesto measurethepeakvoltageoftheexciter(stator)coil.

PeakVoltageDC100Vorabove

★ If the voltage is less than the specified, check the exciter (stator) coil.

EngineStopFunctionCheck

• Disconnecttheenginestopbutton(switch)leadsA.
• Starttheengine.
• Groundthestopbutton(switch)lead[B]ofthemainharnesssidewhiletheengineisrunning.
  ★Iftheenginedoesnotstop,theCDIUnitisdefective.

EngineStopButtonElectricCurrentCheck(KX65A6F \~)

• Disconnecttheenginestopbutton(switch)leadconnector.
• Starttheengine.
• Groundthestopbutton(switch)black/yellowleadofthe magnetoleadwhiletheengineisrunning.
  ★Iftheengine does not stop, replace the CDI Unit.

Appendix

TableofContents

Troubleshooting Guide 14-2

General Lubrication 14-6

Lubrication (Periodic Maintenance) 14-6

Nut, Bolt, and Fastener Tightness 14-7

Tightness Inspection 14-7

Unit Conversion Table 14-8

TroubleshootingGuide

NOTE

○ Thisisnotanexhaustivelist, giving every possible cause foreach problem listed. It is meant simply as a rough guideto assist the troubleshooting for some of them more common difficulties.

EngineDoesn'tStart, Starting Difficulty:

Transmissiongearorbearingseizure

Kickshaftreturnspringbroken

Kickratchetgearnotengaging

Nofuelflow:

Nofuelintank

Fueltapturnedoff

Tankcapairventobstructed

Fueltapclogged

Fuellineclogged

Floatvalveclogged

Engineflooded:

Floatleveltoohigh

Floatvalvewornorstuckopen

Startingtechniquefaulty

(when flooded, kick with the throttle fully opento allow more air to reach the engine.)

Nospark;sparkweak:

Sparkplugdirty,broken,ormaladjusted

Sparkplugcaporhightensionwiringtrouble

Sparkplugcapnotingoodcontact

Sparkplugincorrect

CDIUnittrouble

Ignitioncoiltrouble

Ignitioncoilresistoropen

Flywheelmagnetodamaged

Wiringshortedoropen

Fuel/airmixtureincorrect:

Idleadjustingscrewmaladjusted

Slowjetorairpassageclogged

Aircleanerclogged,poorlysealed,ormissing

Starterjetclogged

CompressionLow:

Sparkplugloose

Cylinderheadnotsufficientlytightened down

Cylinder, pistonworn

Pistonringbad(worn,weak, broken, or sticking)

Pistonringandclearanceexcessive

Cylinderheadgasketdamaged

Cylinderheadwarped

Cylinderbasegasketdamaged

Readvalvedamaged

Cylindernutloose

PoorRunningatLowSpeed:

Sparkweak:

Sparkplugdirty,broken,ormaladjusted

Sparkplugcaporhightensionwiringtrouble

Sparkplugcapshortedornotingoodcontact

Sparkplugincorrect

CDIUnittrouble

Ignitioncoiltrouble

Flywheelmagnetodamaged

Ignition coil lead or CDI Unit lead not in good contact

Fuel/airmixtureincorrect:

Idleadjustingscrewmaladjusted

Slowjetorairpassageclogged

Aircleanerclogged,poorlysealed,ormissing

Chokeplungerstuckopen

Floatleveltoohighortoolow

Fueltankairventobstructed

Carburetorholderloose

Aircleanerductloose

CompressionLow:

Sparkplugloose

Cylinderheadnotsufficientlytightened down

Cylinder, pistonworn

Pistonringbad(worn, weak,broken,or sticking)

Pistonring/landclearanceexcessive

Cylinderheadgasketdamaged

Cylinderheadwarped

Cylinderbasegasketdamaged

Reedvalvedamaged

Cylindernutloose

Other:

CDIUnittrouble

Transmissionoilviscositytoohigh

Brakedragging

PoorRunningorNoPoweratHigh Speed:

Firingincorrect:

Sparkplugdirty,damaged,ormaladjusted

Sparkplugcaporhightensionwiringdam- aged

Sparkplugcapshortedornotingoodcontact

Sparkplugincorrect

CDIUnittrouble

Ignitioncoiltrouble

TroubleshootingGuide

Flywheelmagnetodamaged

IgnitioncoilleadorCDIUnitleadnotingood contact

Fuel/airmixtureincorrect:

Mainjetcloggedorwrongsize

Jetneedleorneedlejetworn

Jetneedleclipinwrongposition

Floatleveltoohighortoolow

Airjetorairpassageclogged

Aircleanerclogged,poorlysealed,ormissing

Chokeplungerstuckopen

Fueltocarburetorinsufficient

Waterorforeignmatterinfuel

Fueltankairventobstructed

Carburetorholderloose

Aircleanerductloose

Fueltapclogged

Fuellineclogged

Compressionlow:

Sparkplugloose

Cylinderheadnotsufficientlytightened down

Cylinder, pistonworn

Pistonringbad(worn,weak,broken,or sticking)

Pistonring/andclearanceexcessive

Cylinderheadgasketdamaged

Cylinderheadwarped

Cylinderbasegasketdamaged

Reedvalvedamaged

Cylindernutloose

Enginerpmwillnotriseproperly:

Chokeplungerstuckopen

Floatleveltoohighortoolow

Mainjetclogged

Throttlevalvedoesnotfullyopen

Aircleanerclogged

Mufflerclogged

Waterorforeignmatterinfuel

Cylinderexhaustportclogged

Brakedragging

Clutchslipping

Overheating

Transmissionoilleveltoohigh

Transmissionoilviscositytoohigh

Crankshaftbearingwornordamaged

Knocking:

Carbonbuiltupincombustionchamber

Fuelpoorqualityorincorrect

Sparkplugincorrect

CDIUnittrouble

Overheating:

Firingincorrect:

Sparkplugdirty, broken, ormaladjusted

Sparkplugincorrect

CDIUnittrouble

Fuel/airmixtureincorrect:

Mainjetcloggedorwrongsize

Fuellevelincarburetorfloatbowltoolow

Carburetorholderloose

Aircleanerpoorlysealed,ormissing

Aircleanerductpoorlysealed

Aircleanerclogged

Compressionhigh:

Carbonbuiltupincombustionchamber

Engineloadfaulty:

Brakedragging

Clutchslipping

Transmissionoilleveltoohigh

Transmissionoilviscositytoohigh

Lubricationinadequate:

Transmissionoilleveltoolow

Transmissionoilpoorqualityorincorrect

Coolantincorrect:

Coolantleveltoolow

Coolantdeteriorated

Coolingsystemcomponentincorrect:

Radiatorclogged

Radiatorcaptrouble

Waterpumpnotrotating

ClutchOperationFaulty:

Clutchslipping:

Noclutchleverplay

Clutchcablemaladjusted

Clutchinnercablecatching

Frictionplatewornorwarped

Steelplatewornorwarped

Clutchspringbrokenorweak

Clutchreleasemechanismtrouble

Clutchhuborhousingunevenlyworn

Clutchnotdisengagingproperly:

Clutchleverplayexcessive

Clutchplatewarpedortoorough

Clutchspringtensionuneven

Transmissionoildeteriorated

Transmissionviscositytoohigh

Transmissionoilleveltoohigh

Clutchhousingfrozenondriveshaft

Clutchreleasemechanismtrouble

GearShiftingFaulty:

Doesn'tintogear;shiftpedaldoesn't

return:

Clutchnotdisengaging

Shiftforkbentorseized

Gearstuckontheshaft

Gearpositioningleverbinding

Shiftreturnspringweakorbroken

Shiftreturnspringpinloose

Shiftmechanismarmspringbroken

Shiftmechanismarmbroken

Shiftdrumbroken

TroubleshootingGuide

Jumpsoutofgear:

Shiftforkworn

Geargrooveworn

Geardogsand/ordogholesworn

Shiftdrumgrooveworn

Gearpositioningleverspringweakorbroken

Shiftforkguidepinworn

Driveshaft, outputshaft, and/orgear splinesworn

Overshifts:

Gearpositioningleverspringweakorbroken

Shiftmechanismarmspringbroken

AbnormalEngineNoise:

Knocking:

CDIUnittrouble

Carbonbuiltupincombustionchamber

Fuelpoorqualityorincorrect

Sparkplugincorrect

Overheating

Pistonslap:

Cylinder/pistonclearanceexcessive

Cylinder, pistonworn

Connectingrodbent

Pistonpin, pistonpinholeworn

Othernoise:

Connectingrodsmallendclearanceexcessive

Connectingrodbigendclearanceexcessive

Pistonringworn, brokenorstuck

Pistonseizureordamaged

Cylinderheadgasketleaking

Exhaustpipeleakingatcylinderheadconnection

Crankshaftrunoutexcessive

Enginemountsloose

Crankshaftbearingworn

Primarygearwornorchipped

AbnormalDriveTrainNoise

Clutchnoise:

Clutchhousing/frictionplateclearanceexcessive

Clutchhousinggear/primarygearbacklash excessive

Metalchipjammedinclutchhousinggear teeth

Transmissionnoise:

Crankcasebearingwornordamaged

Transmissiongearwornorchipped

Metalchipjammedingearteeth

Transmissionoilinsufficientortoothin

Kickratchetgearnotproperlydisengaging fromkickgear

Outputshaftidlegearwornorchipped

Drivechainnoise:

Drivechainadjustedimproperly

Chainworn

Rearand/orenginesprocket(s)worn

Chainlubricationinsufficient

Rearwheelmisaligned

AbnormalFrameNoise:

Frontforknoise:

Oilinsufficientortoothin

Springweakorbroken

Rearshockabsorbernoise:

Shockabsorberdamaged

Discbrakenoise:

Padinstalledincorrectly

Padsurfaceglazed

Discwarped

Calipertrouble

Cylinderdamaged

Othernoise

Bracket, nut, bolt, etc. not properly mountedortightened

ExhaustSmoke:

Excessivewhitesmoke:

Throttlecablemaladjusted

Brownishsmoke:

Aircleanerclogged

Mainjettoolargeoffallenout

Chokeplungerstuckopen

Floatleveltoohigh

Handling and/or Stability

Unsatisfactory:

Handlebarhardtoturn:

ControlCableroutingincorrect

Wiringroutingincorrect

Steeringstemnuttootight

Bearingballdamaged

Bearingracedentedorworn

Steeringstembearinglubricationinadequate

Steeringstembent

Tireairpressuretoolow

Handlebarshakesorexcessivelyvibrates:

Tireworn

Swingarmsleeveorneedlebearingdam- aged

Rimwarped,ornotbalanced

Front, rearaxlerunoutexcessive

Wheelbearingworn

Handlebarclamploose

Steeringstemheadnutloose

Handlebarpullstooneside:

Framebent

TroubleshootingGuide

Wheelmisalignment

Swingarmbentortwisted

Swingarmpivotshafrunoutexcessive

Steeringmaladjusted

Steeringstembent

Frontforklegbent

Right/leftfrontforkoilleveluneven

Shockabsorptionunsatisfactory:

(Toohard)

Frontforkoilexcessive

Frontforkoilviscositytoohigh

Frontforklegbent

Tireairpressuretoohigh

Rearshockabsorbermaladjusted

(Toosoft)

Frontforkoilinsufficientand/orleaking

Frontforkoilviscositytoolow

Frontfork, rearshockabsorberspringweak

Rearshockabsorbergasleaking

Rearshockabsorbermaladjusted

BrakeDoesn'tHold:

Discbrake:

Airinthebrakeline

Padordiscworn

Brakefluidleak

Discwarped

Contaminatedpads

Brakefluiddeteriorated

Primaryorsecondarycupdamaged

Mastercylinderscratchedinside

Brakemaladjustment(leverorpedalplay excessive)

14-6APPENDIX

GeneralLubrication

Lubrication(PeriodicMaintenance)

• Beforelubricatingeachpart,cleanoffanyrustyspotswith rustremoverandwipeoffanygrease,oil,dirt,orgrime.
• Lubricatethepointslistedbelowwithindicatedlubricant.

NOTE

○ Wheneverthevehiclehasbeenoperatedunder wetorrainyconditions,orespeciallyafterusing a high-pressurewaterspray,performthegenerallubrication.

Pivots:LubricatewithMotorOil

ClutchLever

BrakeLever

KickPedal

ShiftPedal

DriveChain

Points:LubricatewithGrease[A].

ClutchInnerCableUpperandLowerEnds

ThrottleInnerCableUpperEnds

SwingarmPivot

Tie-RodPivot

RockerarmPivot

SteeringStemBearing

Cables: Lubricate with Rust Inhibitor.

ThrottleCables

ClutchCableA

• With the cabled disconnected at the both ends, the cable A should move freely within the cable housing.
  ★ Ifcablemovementisnotfreeafterlubricating,ifthecable isfrayed,orifthecablehousingiskinked,replacethe cable.

Line drawing of hands holding a syringe with a pointer and labeled point A (no text or symbols beyond label)

Nut, Bolt, and Fastener Tightness

TightnessInspection

- Checkthetightnessofboltsandnutslistedhere. Also, checktoseethateachcotterpinisinplaceandingood condition.

NOTE

○ Fortheenginefasteners, check the tightness of them when the engine is cold (at room temperature).

★ Ifthereareloosefasteners,retorquethemtothespecifiedtorquefollowingthespecifiedtighteningsequence. Refertotheappropriatechapterfortorquespecifications. Iftorquespecificationsarenotintheappropriatechapter, seetheStandardTorqueTable.Foreachfastener,first loosenitby1/2turn,thentightenit.

★Ifcotterpinsaredamaged, replacethemwithnewones.

Nut,BoltandFastenertobechecked

Wheels:

SpokeNipples

FrontAxleNut

RearAxleNut

FinalDrive:

ChainAdjusterLocknuts

Brakes:

MasterCylinderClampBolts

CaliperMountingBolts

BrakePedalMountingBolt

Suspension:

FrontForkClampBolts

RearShockAbsorberMountingBoltandNut

SwingarmPivotShaftNut

Tie-rodMountingNut

Steering:

SteeringStemHeadNut

HandlebarClampBolts

SteeringStemNut

Engine:

EngineMountingNuts

EngineBracketNuts

CylinderHeadNuts

ShiftPedalBolt

MufflerMountingBoltandNut

KickPedalBolt

Others:

RearFrameMountingBolts

FrontFenderMountingBolt

PrefixesforUnits:

PrefixSymbol		Power
megaM×1000000
kilok×1000
centic× 0 . 0 1
millim×0.001
microμ	×0.000001

UnitsofMass:

kg	×	2.205	=	lb
g	×	0.03527	=	oz

UnitsofVolume:

L	×	0.2642	=	gal (US)
L	×	0.2200	=	gal (imp)
L	×	1.057	=	qt (US)
L	×	0.8799	=	qt (imp)
L	×	2.113	=	pint(US)
L	×	1.816	=	pint (imp)
mL	×	0.03381	=	oz (US)
mL	×	0.02816	=	oz (imp)
mL	×	0.06102	=	cu in

UnitsofForce:

N	×	0.1020	=	kg
N	×	0.2248	=	lb
kg	×	9.807	=	N
kg	×	2.205	=	lb

UnitsofLength:

km	×	0.6214	=	mile
m	×	3.281	=	ft
mm	×	0.03937	=	in

UnitsofTorque:

N·m	×	0.1020	=	kgf·m
N·m	×	0.7376	=	ft·lb
N·m	×	8.851	=	in·lb
kgf·m	×	9.807	=	N·m
kgf·m	×	7.233	=	ft·lb
kgf·m	×	86.80	=	in·lb

UnitsofPressure:

kPa	×	0.01020	=	kgf/cm ^2
kPa	×	0.1450	=	psi
kPa	×	0.7501	=	cmHg
kgf/cm ^2	×	98.07	=	kPa
kgf/cm ^2	×	14.22	=	psi
cmHg	×	1.333	=	kPa

UnitsofSpeed:

km/h

×

0.6214

=

mph

UnitsofPower:

kW	×	1.360	=	PS
kW	×	1.341	=	HP
PS	×	0.7355	=	kW
PS	×	0.9863	=	HP

UnitsofTemperature:

MODELAPPLICATION

YearModel	BeginningFrameNo
2000KX65-A1		JKBKEAC□YA000001orJKAKX065AAA000001
2001KX65-A2		JKBKXEAC□1A009001orJKBKX065AAA009001
2002KX65-A3		JKBKXEAC□2A016001orJKBKX065AAA016001
2003KX65-A4		JKBKXEAC□3A027001orJKBKX065AAA027001
2004KX65-A5		JKBKXEAC□4A036001orJKBKX065AAA036001
2005KX65-A6		JKBKXEAC□5A042001orJKBKX065AAA042001
2006KX65A6F		JKBKXEAC□6A048001orJKBKX065AAA048001
2007KX65A7F		JKBKXEAC□7A054001JKBKX065AAA054001
2008KX65A8F		JKBKXEAC□8A059001orJKBKX065AAA059001
2009KX65A9F		JKBKXEAC□9A065001orJKBKX065AAA065001
2010KX65AAF		JKBKXEAC□AA070001orJKBKX065AAA070001
2011KX65ABF		JKBKXEAC□BA072001orJKBKX065AAA072001

□: Thisdigitintheframenumberchangesfromonemachinetoanother.