Kawasaki KX65 User Manual

KX65

Motorcycle

Service Manual

Quick Reference Guide

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General Information 1

Fuel System 2

Cooling System 3

Engine Top End 4

Engine Right Side 5

Engine Removal/Installation 6

Engine Bottom End/Transmission 7

Wheels/Tires 8

This quick refe
you in locating a desired topic or pro­cedure.

•Bend the pag
black tab of the desired chapter num­ber with the black tab on the edge at
each table

•Refer to the sectional table of contents
for the exact pages to locate the spe­cific to

pic required.

rence guide will assist

es back to match the

of contents page.

Final Drive 9

Brakes 10

Suspension 11

Steering 12

Electrical System 13

Appendix 14

KX65

Motorcycle

Service Manual

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Assurance Division/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.

© 1999 Kawasaki Heavy Industries, Ltd. 12th Edition (1) : Mar. 1, 2010

LIST OF ABBREVIATIONS

A ampere(s) lb pound(s)

ABDC after bottom dead center m meter(s)

AC

ATDC after top dead center

BBDC before bottom dead center

BDC bottom dead center PS horsepower

BTDC before top dead center psi pound(s) per square inch

°C degree(s) Celsius r revolution

DC direct 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

alternating current min

N

Pa

liter(s)

minute(s)

newton(s)

pascal(s)

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

Foreword

This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in­formation to make it useful to the owner who de­sires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce­dures must be understood in order to carry out
maintenance and repair satisfactorily. When­ever the owner has insufficient experience or
doubts as to his ability to do the work, all ad­justments, maintenance, and repair should be
carried out only by qualified mechanics.

In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor­oughly familiarize yourself with the procedures
before starting work, and then do the work care­fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may ad­versely affect safe operation.

To get the longest life out of your motorcycle:

Follow the Periodic Maintenance Chart in the

•

Service Manual.

Be alert for problems and non-scheduled

•

maintenance.

Use proper tools and genuine Kawasaki mo-

•

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki Motorcycles are introduced by the

Service Manual. Genuine parts provided as

spare parts are listed in the Parts Catalog.

Follow the procedures in this manual care-

•

fully. Don’t take shortcuts.

Remember to keep complete records of main-

•

tenance and repair with dates and any new

parts installed.

How to Use this M

In this manual, the product is divided into its
major systems and these systems make up the
manual’s chap

The Quick Reference Guide shows you all
of the product’s system and assists in locating
their chapter
comprehensive Table of Contents.

Foe Example, if you want ignition coil infor­mation, use
cate the Electrical System chapter. Then, use

ters.

s. Each chapter in turn has its own

the Quick Reference Guide to lo-

anual

the Table of Contents on the first page of the
chapter to find the ignition coil section.

Whenever you see these symbols, heed their
instructions! Always follow safe operating and
maintenance practices.

DANGER

DANGER indicates a hazardous situa-

tion which, if not avoided, will result in

death or serious injury.

WARNING

WARNING indicates a hazardous situa-

tion which, if not avoided, could result

in death or serious injury.

CAUTION

CAUTION indicates a hazardous situa-

tion which, if not avoided, could result

in minor or moderate injury.

NOTICE

NOTICE is used to address practices not

related to personal injury.

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

NOTE

This note symbol indicates points of p ar-

○

ticular interest for more efficient and con-

venient operation.

Indicates a procedural step or work to be

•

done.

Indicates a procedural sub-step or how to do

○

the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to

take based on the results of the test or inspec-

tion in the procedural step or sub-step it fol-

lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec­ified tightening torque, oil, grease or a locking
agent during assembly.

GENERAL INFORMATION 1-1

General Information

Table of Contents

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

1

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly opera­tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra­tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.

Especially note the following:

(1) Dirt

Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten
the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or
metal filings.

(2) Battery Ground

Disconnect the ground (–) cable from the battery before performing any disassembly operations
on the motorcycle. This prevents the engine from accidentally turning over while work is being
carried out, sparks from being generated while disconnecting the cables from electrical parts, as
well as damage to the electrical parts themselves. For reinstallation, first connect the positive
cable to the positive (+) terminal of the battery

(3) Installation, Assembly

Generally, installation or assembly is the reverse of removal or disassembly. However, if instal­lation or assembly sequence is given in this Service Manual, follow it. Note parts locations and
cable, wire, and hose routing during removal or disassembly so they can be installed or assem­bled in the same way. It is preferable to mark and record the locations and routing whenever
possible.

(4) Tightening Sequence

When installing bolts, nuts, or screws for which a tightening sequence is given in this Service
Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or
screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has
been installed in its proper location. Then, tighten them to the specified torque in the tightening
sequence and method indicated. If tightening sequence instructions are not given, tighten them
evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws
that are retaining the part a 1/4-turn before removing them.

(5) Torque

When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage. Use a good quality, reliable torque wrench.

(6) Force

Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removing screws held by non-permanent locking
agent) in order to avoid damaging the screw heads.

(7) Edges

Watch for sharp edges, as they could cause injury through careless handling, especially during
major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine
or turning it over.

(8) High-Flash Point Solvent

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

(9) Gasket, O-ring

Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter
from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent
oil or compression leaks.

(10)Liquid Gasket, Locking Agent

Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used.
Apply them sparingly. Excessive amount may block engine oil passages and cause serious dam­age.

GENERAL INFORMATION 1-3

Before Servicing

(11)Press

When using a press or driver to install a part such as a wheel bearing, apply a small amount of

oil to the area where the two parts come in contact to ensure a smooth fit.

(12)Ball Bearing and Needle Bearing

Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any
ball or needle bearings that were removed with new ones. Install bearings with the manufacturer
and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the
end of the race that contacts the press fit portion, and press it evenly over the base component.

(13)Oil Seal and Grease Seal

Replace any oil or grease seals that were removed with new ones, as removal generally dam­ages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a
force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless
instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s marks,
press it in with the marks facing out.

(14)Circlip, Retaining Ring, and Cotter Pin

When installing circlips and retaining rings, take care to compress or expand them only enough
to install them and no more. Install the circlip with its chamfered side facing load side as well.

Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as re­moval weakens and deforms them. If old ones are reused, they could become detached while
the motorcycle is driven, leading to a major problem.

(15)Lubrication

Engine wear is generally at its maximum while the engine is warming up and before all the sliding
surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding
surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative
quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off
and apply fresh grease or oil. Some oils and greases in particular should be used only in certain
applications and may be harmful if used in an application for which they are not intended.

(16)Direction of Engine Rotation

To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Pos­itive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper
adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as
well.

(17)Replacement Parts

When there is a replacement instruction, replace these parts with new ones every time they are
removed.

Replacement parts will be damaged or lose their o riginal function once they are removed. There­fore, always replace these parts with new ones every time they are removed. Although the pre­viously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and
cotter pin have not been so designated in their respective text, they are replacement parts.

(18)Electrical Leads

All the electrical leads are either one-color or two-color. A two-color lead is identified first by
the primary color and then the stripe color. For example, a yellow lead with thin red stripes is
referred to as a “yellow/red” lead; it would be a “red/yellow” lead if the colors were reversed.
Unless instructed otherwise, electrical leads must be connected to leads of the same color.

Two-Color Electrical

1-4 GENERAL INFORMATION

Before Servicing

(19)Inspection

When parts have been disassembled, visually inspect these parts for the following conditions

or other damage. If there is any doubt as to the condition of them, replace them with new ones.

Abrasion Crack Hardening Warp

Bent Dent

Color change

(20)Specifications

Specification terms are defined as follows:
"Standards" show dimensions or performances which brand-new parts or systems have.
"Service Limits" indicate the usable limits. If the measurement shows excessive wear or dete-

riorated performance, replace the damaged parts.

Deterioration

Scratch

Seizure

Wear

Model Identification

KX65-A1 Left Side View

GENERAL INFORMATION 1-5

KX65-A1 Right Side View

1-6 GENERAL INFORMATION

General Specifications

Items KX65-A1 ∼ A2

Dimensions

Overall Length 1 580 mm 1 590 mm

Overall Width 690 mm (KX65-A1), 730 mm (KX65-A2) 760 mm

Overall Height 925 mm (KX65-A1), 935 mm (KX65-A2) 955 mm

Wheelbase 1110mm 1 120 mm

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 26.5 kg 28.5 kg

Rear 29.5 kg 31.5 kg

Fuel Tank Capacity

Engine

Type 2-stroke, single cylinder, piston reed valve ←

Cooling System Liquid-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) ←

Spark Plug NGK BR10EG (US) NGK B10EG ←

Port Timing

Intake:

Open Full open ←

Close — ←

Scavenging:

Open 61.8° BBDC ←

Close 61.8° ABDC ←

Duaration 123.6° ←

Exhaust:

Open 91.5° BBDC ←

Close 91.5° ABDC ←

Duaration 183° ←

Lubrication System
(Gasoline : Oil)

3.8 L ←

Petrol mix (32:1) ←

KX65-A3 ∼ A6, A6F

∼ ABF

20.5ºBTDC

@7 100 r/min (rpm)

(KX65A6F ∼)

NGK BR10EG

(KX65A6F ∼)

General Specifications

GENERAL INFORMATION 1-7

Items KX65-A1 ∼ A2

Drive Train

Primary Reduction System:

Type Gear ←

Reduction Ratio 3.500 (77/22) ←

Clutch Type Wet, multi disc ←

Transmission:

Type 6-speed, constant mesh, return shift ←

Gear Ratios:

1st 2.846 (37/13) ←

2nd 2.125 (34/16) ←

3rd 1.722 (31/18) ←

4th 1.428 (30/21) ←

5th 1.217 (28/23) ←

6th 1.083 (26/24) ←

Final Drive System:

Type

Reduction Ratio

Overall Drive Ratio 13.416 @Top gear 13.703 @Top gear

Transmission Oil:

Grade API SG, SH, SJ, SL or SM with JASO MA,

Viscosity SAE 10W-40 ←

Capacity 0.5 L ←

Frame

Type Tubular, semi-double cradle ←

Steering Angle 40° to either side

Caster (Rake Angle) 26.5° 27°

Trail 60 mm ←

Front Tire:

Size 60/100-14 30M ←

Type tube type ←

Rear Tire:

Size 80/100-12 41M ←

Type tube type ←

Rim Size:

Front 14 × 1.40 ←

Rear 12 × 1.60 ←

Front Suspension:

Type Telescopic fork ←

Wheel Travel 210 mm ←

Rear Suspension:

Type Swingarm (Uni-trak) ←

Wheel Travel 225 mm 240 mm

Chain drive

3.538 (46/13) 3.615 (47/13)

MA1 or MA2

KX65-A3 ∼ A6, A6F

∼ ABF

←

←

←

1-8 GENERAL INFORMATION

General Specifications

Items KX65-A1 ∼ A2

Brake Type:

Front and Rear Single disc ←

Effective Disc Diameter:

Front 154.8 mm ←

Rear 146 mm ←

Specifications are subject to change without notice, and may not apply to every country.

US: United States Model

KX65-A3 ∼ A6, A6F

∼ ABF

GENERAL INFORMATION 1-9

Periodic Maintenance Chart

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

condition.

FREQUENCY

OPERATION

Clutch - adjust

Clutch and friction plates - inspect †

Throttle cable - adjust

Spark plug - clean, gap †

Air cleaner element - clean

Air cleaner element - replace When damaged

Carburetor - inspect/adjust

Transmission oil - change

Piston and piston ring - clean/inspect †

Cylinder head, cylinder - inspect

Muffler body - clean/inspect †

Muffler body packing - change

Small end bearing - inspect †

Kick pedal and shift pedal - clean

Exhaust pipe O-ring - replace

Engine sprocket - inspect †

Coolant - inspect †

Water hoses, connections - inspect †

Reed valve - inspect †

Brake adjustment - inspect †

Brake pad wear - inspect †

Brake fluid level - inspect †

Brake fluid - change

Brake master cylinder cup and dust seal - replace Every 2 years

Brake caliper fluid seal and dust seal - replace Every 2 years

Brake hose - replace Every 4 years

After
each

race (or

2.5 hr.)

•

•

•

•

•

•

•

•

•

•

•

•

Every

3 races

(or 7.5

hr.)

•

R

•

•

•

•

•

•

•

Every
5 races
(or 12.5

hr.)

R

R

10 races

•

Every 2 years

Every

(or 25

hr.)

R

As

required

R

Brake hoses, connections - inspect †

Spoke tightness and rim runout - inspect †

Drive chain - adjust

Drive chain - lubricate

Drive chain wear - inspect †

Drive chain slipper and guide - replace When damaged

Front fork - inspect/clean

Front fork oil - change 1st time after 2 races, then every 5 races

Nuts, bolts, fasteners - inspect †

Fuel system - clean

Fuel hose - replace Every 4 years

•

•

•

•

•

•

•

•

1-10 GENERAL INFORMATION

Periodic Maintenance Chart

FREQUENCY

OPERATION

Fuel hoses, connections - inspect †

Steering play - inspect †

Steering stem bearing - grease

Rear sprocket - inspect †

General lubrication - perform

Wheel bearing - inspect †

Swing arm and Uni-Trak linkage pivots - grease

Swing arm and Uni-Trak linkage pivots - inspect †

Rear shock oil - replace 1st time after 2 races, then every 5 races

†: Replace, add, adjust, clean or torque if necessary.

R: Replace

After
each

race (or

2.5 hr.)

•

•

•

Every

3 races

(or 7.5

hr.)

Every

5 races

(or 12.5

hr.)

•

•

•

•

Every

10 races

(or 25

hr.)

•

As

required

GENERAL INFORMATION 1-11

Torque and Locking Agent

Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently
tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The
following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a
non-permanent locking agent or liquid gasket.

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

Letters used in the "Remarks" column mean:

L: Apply a non-permanent locking agent to the threads.

Lh: Left-hand Threads.

S: Tighten the fasteners following the specified sequence.

Fastener

Fuel System

Rear Frame Mounting Bolts 34 3.5 25

Carburetor Clamp Screws 1.5 0.15 13 in·lb

Carburetor Holder Mounting Bolts 8.8 0.90 78 in·lb

Air Cleaner Housing Plate Nuts

Air Cleaner Housing Mounting Bolts

Reed Valve Screws

Cooling System

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

Engine Top End

Cylinder Head Nuts

Spark Plug

Cylinder Nuts 25 2.5 18

Muffler Mounting Bolts 8.8 0.90 78 in·lb L

Expansion Chamber Damper Mounting Bolt,
Nut

Inner Pipe Mounting Bolts 5.9 0.6 52 in·lb L

Engine Right Side

Primary Gear Nut (KX65A6F ∼) 49 5.0 36 Lh

Clutch Spring Bolts 9.3 0.95 82 in·lb

Clutch Hub Bolt 64 6.5 47

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

N·m

3.0 0.31 27 in·lb

8.8 0.90 78 in·lb

9.8 1.0 87 in·lb

25 2.5 18

26 2.6 19

8.8 0.90 78 in·lb

Torque

Remarks

kgf·m ft·lb

1-12 GENERAL INFORMATION

Torque and Locking Agent

Fastener

Engine Removal/Installation

Engine Mounting Nuts 25 2.5 18

Engine Mounting Nuts (KX65-A3 ∼) 29 3.0 21

Swing Arm Pivot Shaft Nut 69 7.0 51

Engine Bottom End/Transmission

Cylinder Stud

Crankcase Bolts

Shift Pedal Bolt 8.8 0.90 78 in·lb

Engine Oil Drain Plug 20 2.0 15

Bearing Retaining Screws 8.8 0.90 78 in·lb

Shift Drum Operating Plate Bolt 24 2.4 17 L

Shift Drum Plate Mounting Screws 5.2 0.53 46 in·lb L

Gear Set Lever Screw 8.8 0.90 78 in·lb

Flywheel Nut 29 3.0 21

Wheels/Tires

Front Axle Nut 79 8.0 58

Rear Axle Nut 79 8.0 58

Spoke Nipple Not less

Final Drive

Rear Axle Nut 79 8.0 58

Rear Sprocket Bolts

Brakes

Caliper Mounting Bolts (Front, Rear) 25 2.5 18

Brake Hose Banjo Bolts 25 2.5 18

Master Cylinder Clamp Bolts 8.8 0.90 78 in·lb S

Rear Master Cylinder Mounting Screws 9.8 1.0 87 in·lb

Rear Master Cylinder Push Rod Locknut 18 1.8 13

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

Brake Pedal Mounting Bolt 25 2.5 18

Brake Lever Adjuster locknut 4.9 0.50 43 in·lb

Brake Pad Bolts 18 1.8 13

Suspension

Front Fork Clamp Bolts (Upper) 20 2.0 14

Front Fork Clamp Bolt (Lower) 29 3.0 22

Fork Bottom Allen Bolt 20 2.0 14 L

Front Fork Top Plug 22 2.2 16

Swingarm Pivot Shaft Nut 69 7.0 51

Rear Shock Absorber Mounting Bolt (Upper)

Rear Shock Absorber Mounting Nut (Lower)

Tie-rod Mounting Nuts (Front, Rear)

N·m kgf·m ft·lb

– – –

8.8 0.90 78 in·lb

than 1.5

26 2.7 20

39 4.0 29

34 3.5 25

59 6.0 43

Torque

Not less

than 0.15

Remarks

L (Planted

Not less

than 13

in·lb

Side)

Torque and Locking Agent

GENERAL INFORMATION 1-13

Fastener

Rocker Arm Pivot Nut 83 8.5 61

Caliper Mounting Bolts

Rear Frame Mounting Bolts 34 3.5 25

Steering

Steering Stem Head Nut 44 4.5 33

Steering Stem Nut 2.9 0.30 26 in·lb

Handlebar Clamp Bolts

Clutch Lever Clamp Bolts

Front Fork Clamp Bolts (Upper)

Front Fork Clamp Bolts (Lower) 29 3.0 22

Electrical System

Magneto Cover Bolts 8.8 0.90 78 in·lb

Flywheel Nut 29 3.0 21

Stator Plate Mounting Screws

Ignition Coil Mounting Bolts

CDI Unit Mounting Bolts 8.8 0.90 78 in·lb

Spark Plug 26 2.6 19

N·m kgf·m ft·lb

25 2.5 18

25 2.5 18

8.8 0.90 78 in·lb

20 2.0 15

4.9 0.50 43 in·lb

8.8 0.90 78 in·lb

Torque

Remarks

The table below relating tightening torque to thread diameter, lists the basic torque the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads dia. Torque

(mm) 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

1-14 GENERAL INFORMATION

Special Tools and Sealants

Bearing Puller Adapter:
57001-136

Steering Stem Bea ring Driver:
57001-137

Inside Circlip Pliers:
57001-143

Fork Cylinder Holder Handle:
57001-183

Flywheel Puller, M12 × 1.75:
57001-252

Piston Pin Puller A ssembly:
57001-910

Outside Circlip Pliers:
57001-144

Bearing Puller:
57001-158

Fork Cylinder Holder Adapter:
57001-1011

Oil Seal & Bearing Remover:
57001-1058

Special Tools and Sealants

GENERAL INFORMATION 1-15

Rim Protector:
57001-1063

Bead Breaker Assembly:
57001-1072

Head Pipe Outer Race Press Shaft:
57001-1075

Hook Wrench R37.5, R42:
57001-1101

Head Pipe Outer Race Driver, 46.5:
57001-1106

Head Pipe Outer Race Remover ID > 37 mm:
57001-1107

Steering Stem Bearing Driver Adapter, 29.7:
57001-1092

Steering Stem Nut Wrench:
57001-1100

Bearing Driver Set:
57001-1129

Fork Outer Tube Weight:
57001-1218

1-16 GENERAL INFORMATION

Special Tools and Sealants

Front Fork Oil Seal Driver:
57001-1219

Jack:
57001-1238

Fork Oil Level Gauge:
57001-1290

Peak Voltage Adapter:
57001-1415

Crank Shaft Jig:
57001-1439

Graduated Cylinder & Tube:
57001-1584

Crankcase Splitting Tool Assembly:
57001-1362

Hand Tester:
57001-1394

Flywheel & Pulley Holder:
57001-1605

Fuel Level Gauge Adapter, M16 × 1:
57001-1661

Special Tools and Sealants

GENERAL INFORMATION 1-17

Liquid Gasket, TB1211:
56019-120

Liquid Gasket, TB1105B:
92104-002

1-18 GENERAL INFORMATION

Cable, Wire and Hose Routing

1. Throttle Cable

2. Carburetor

3. Breather Hose

4. Air Vent Hose

5. Overflow Hose

6. The hoses are passed from the left side of
the engine through the clamp in order of
the air vent hose, the overflow hose and
the breather hose as shown in figure.

7. CDI Unit (KX65-A1 ∼ A6)

8. Clamp

9. Rubber Damper (Note its installing direc­tion.)

10. Clutch Cable

11. Engine Stop Button Lead

12. Band

13. Install the kick pedal so that it should be
parallel to the frame as shown in figure.

14. KX65-A1 ∼ A2

15. KX65-A3 ∼ A6

Cable, Wire and Hose Routing

GENERAL INFORMATION 1-19

1. Breather Hose

2. Run the throttle cable under the breather hose.

3. Radiator

4. CDI Unit (KX65-A1 ∼ A6)

5. Clamp (KX65-A1 ∼ A6)

6. Throttle Cable

7. Clamp as shown in figure. (Be sure the clamp s crew position is inside.)

8. Clamp as shown in figure.

9. Cylinder Head

10. Cylinder

11. Water Pump Cover

12. Engine Stop Button Lead (KX65A6F ∼)

1-20 GENERAL INFORMATION

Cable, Wire and Hose Routing

1. Clamp

2. CDI Unit (KX65-A1 ∼ A6)

3. Band

4. Clamp the magneto leads at the upper part of the left on the carburetor holder.

5. Magneto Leads

6. Shift Pedal

7. 19 ±10 mm (Shift Pedal Position)

8. Engine Stop Button Lead

9. Ignition Coil

10. Engine Stop Button Lead Ground

11. CDI Unit Ground Lead

Cable, Wire and Hose Routing

GENERAL INFORMATION 1-21

1. Front Brake Reservoir

2. Banjo Bolts

3. Clamp

4. Front Brake Disk

5. Bleed Valves

6. Front Brake Caliper

7. Rear Brake Caliper

8. Rear Brake Disk

9. Rear Brake Reservoir

10. Rear Brake Master Cylinder

11. Bend the cotter pin end by along the joint pin.

12. White paint mark

1-22 GENERAL INFORMATION

Cable, Wire and Hose Routing

KX65A6F ∼

1. Throttle Cable

2. Clutch Cable

3. Band

4. Engine Stop Button Lead

5. Clamp

6. CDI unit

7. Band

8. CDI unit Gro

und Lead

9. Ignition Coil Primary Lead

10. Ignition Coil Grou

11. Ignition Coil

12. Band

13. Clamp the Magnet

14. KX65A6F ∼ A8F

15. KX65A9F ∼

nd Lead

o Lead