2001 Kawasaki KX65-A2 Service Repair Manual

MODELAPPLICATION

Year Model

BeginningFrameNo.

2000 KX65-A1 JKBKEAC□YA000001 JKAKX065AAA000001

2001 KX65-A2 JKBKXEAC□1A009001 JKBKX065AAA009001

2002 KX65-A3 JKBKXEAC□2A016001 JKBKX065AAA016001 2003 KX65-A4 JKBKXEAC□3A027001 JKBKX065AAA027001 2004 KX65-A5 JKBKXEAC□4A036001 JKBKX065AAA036001 2005 KX65-A6 JKBKXEAC□5A042001 JKBKX065AAA042001

2006 KX65A6 JKBKXEAC□6A048001 JKBKX065AAA048001

2007 KX65A7 JKBKXEAC□7A054001 JKBKX065AAA054001

2008 KX65A8 JKBKXEAC□8A059001 JKBKX065AAA059001

2009 KX65A9 JKBKXEAC□9A065001 JKBKX065AAA065001

2010 KX65AA JKBKXEAC□AA070001 JKBKX065AAA070001

2011 KX65AB JKBKXEAC□BA072001 JKBKX065AAA072001 2012 KX65AC JKBKXEAC□CA075001 JKBKX065AAA075001 2013 KX65AD

JKBKXEAC□DA078001 JKBKX065AAA078001 2014 KX65AE JKBKXEAC□EA081001 JKBKX065AAA081001

Motorcycle

Thisquickreferenceguidewillassist youinlocatingadesiredtopicorprocedure.

•Bendthepagesbacktomatchthe blacktabofthedesiredchapternumberwiththeblacktabontheedgeat eachtableofcontentspage.

•Refertothesectionaltableofcontents fortheexactpagestolocatethespecifictopicrequired.

Motorcycle ServiceManual

Allrightsreserved.Nopartsofthispublicationmaybereproduced,storedinaretrievalsystem,or transmittedinanyformorbyanymeans,electronicmechanicalphotocopying,recordingorotherwise, withoutthepriorwrittenpermissionofQualityAssuranceDivision/Motorcycle&EngineCompany/Kawasaki HeavyIndustries,Ltd.,Japan.

Noliabilitycanbeacceptedforanyinaccuraciesoromissionsinthispublication,althougheverypossible carehasbeentakentomakeitascompleteandaccurateaspossible.

Therightisreservedtomakechangesatanytimewithout priornoticeandwithoutincurringanobligation tomakesuchchangestoproductsmanufacturedpreviously.SeeyourMotorcycledealerforthelatest informationonproductimprovementsincorporatedafterthispublication.

Allinformationcontainedinthispublicationisbasedon thelatestproductinformationavailableatthetime ofpublication.Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmay notdepictactualmodelcomponentparts.

©1999KawasakiHeavyIndustries,Ltd.15thEdition(0):Mar.15,2013

LISTOFABBREVIATIONS

A ampere(s) lb pound(s)

ABDC afterbottomdeadcenter m meter(s)

AC alternatingcurrent min minute(s)

ATDC aftertopdeadcenter N newton(s)

BBDC beforebottomdeadcenter Pa pascal(s)

BDC bottomdeadcenter PS horsepower

BTDC beforetopdeadcenter psi pound(s)persquareinch °C degree(s)Celsius r revolution DC directcurrent rpm revolution(s)perminute F farad(s) TDC topdeadcenter °F degree(s)Fahrenheit TIR totalindicatorreading ft foot,feet V volt(s) g gram(s) W watt(s) h hour(s) Ω ohm(s) L liter(s)

Thismotorcycleisdesignedforariderweighinglessthan121pounds(55kg).Exceedingthis limitcoulddamagethemotorcycle.

Foreword

Thismanualisdesignedprimarilyforuseby trainedmechanicsinaproperlyequippedshop. However,itcontainsenoughdetailandbasicinformationtomakeitusefultotheownerwhodesirestoperformhisownbasicmaintenanceand repairwork.Abasicknowledgeofmechanics, theproperuseoftools,andworkshopproceduresmustbeunderstoodinordertocarryout maintenanceandrepairsatisfactorily.Whenevertheownerhasinsufficientexperienceor doubtsastohisabilitytodothework,alladjustments,maintenance,andrepairshouldbe carriedoutonlybyqualifiedmechanics.

Inordertoperformtheworkefficientlyand toavoidcostlymistakes,readthetext,thoroughlyfamiliarizeyourselfwiththeprocedures beforestartingwork,andthendotheworkcarefullyinacleanarea.Wheneverspecialtoolsor equipmentarespecified,donotusemakeshift toolsorequipment.Precisionmeasurements canonlybemadeiftheproperinstrumentsare used,andtheuseofsubstitutetoolsmayadverselyaffectsafeoperation.

Togetthelongestlifeoutofyourmotorcycle:

• FollowthePeriodicMaintenanceChartinthe ServiceManual.

• Bealertforproblemsandnon-scheduled maintenance.

• UsepropertoolsandgenuineKawasakimotorcycleparts.Specialtools,gauges,and testersthatarenecessarywhenservicing KawasakiMotorcyclesareintroducedbythe ServiceManual.Genuinepartsprovidedas sparepartsarelistedinthePartsCatalog.

• Followtheproceduresinthismanualcarefully.Don’ttakeshortcuts.

• Remembertokeepcompleterecordsofmaintenanceandrepairwithdatesandanynew partsinstalled.

HowtoUsethisManual

Inthismanual,theproductisdividedintoits majorsystemsandthesesystemsmakeupthe manual’schapters.

TheQuickReferenceGuideshowsyouall oftheproduct’ssystemandassistsinlocating theirchapters.Eachchapterinturnhasitsown

comprehensiveTableofContents.

FoeExample,ifyouwantignitioncoilinformation,usetheQuickReferenceGuidetolocatetheElectricalSystemchapter.Then,use theTableofContentsonthefirstpageofthe chaptertofindtheignitioncoilsection.

Wheneveryouseethesesymbols,heedtheir instructions!Alwaysfollowsafeoperatingand maintenancepractices.

DANGER

DANGERindicatesahazardoussituationwhich,ifnotavoided,willresultin deathorseriousinjury.

WARNING

WARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresult indeathorseriousinjury.

NOTICE

NOTICEisusedtoaddresspracticesnot relatedtopersonalinjury.

Thismanualcontainsfourmoresymbols whichwillhelpyoudistinguishdifferenttypes ofinformation.

NOTE

○

NOTEindicatesinformationthatmayhelp orguideyouintheoperationorserviceof thevehicle.

• Indicatesaproceduralsteporworktobe done.

○

Indicatesaproceduralsub-steporhowtodo theworkoftheproceduralstepitfollows.It alsoprecedesthetextofaNOTE.

Indicatesaconditionalsteporwhatactionto takebasedontheresultsofthetestorinspectionintheproceduralsteporsub-stepitfollows.

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

BeforeServicing

Beforestartingtoperformaninspectionserviceorcarryoutadisassemblyandreassemblyoperationonamotorcycle,readtheprecautionsgivenbelow.Tofacilitateactualoperations,notes,illustrations,photographs,cautions,anddetaileddescriptionshavebeenincludedineachchapterwherever necessary.Thissectionexplainstheitemsthatrequireparticularattentionduringtheremovaland reinstallationordisassemblyandreassemblyofgeneralparts.

Especiallynotethefollowing:

(1)Dirt

Beforeremovalanddisassembly,cleanthemotorcycle.Anydirtenteringtheenginewillshorten thelifeofthemotorcycle.Forthesamereason,beforeinstallinganewpart,cleanoffanydustor metalfilings.

(2)BatteryGround

Disconnecttheground(–)cablefromthebatterybeforeperforminganydisassemblyoperations onthemotorcycle.Thispreventstheenginefromaccidentallyturningoverwhileworkisbeing carriedout,sparksfrombeinggeneratedwhiledisconnectingthecablesfromelectricalparts,as wellasdamagetotheelectricalpartsthemselves.Forreinstallation,firstconnectthepositive cabletothepositive(+)terminalofthebattery

(3)Installation,Assembly

Generally,installationorassemblyisthereverseofremovalordisassembly.However,ifinstallationorassemblysequenceisgiveninthisServiceManual,followit.Notepartslocationsand cable,wire,andhoseroutingduringremovalor disassemblysotheycanbeinstalledorassembledinthesameway.Itispreferabletomarkandrecordthelocationsandroutingwhenever possible.

(4)TighteningSequence

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

(5)Torque

WhentorquevaluesaregiveninthisServiceManual,usethem.Eithertoolittleortoomuch torquemayleadtoseriousdamage.Useagoodquality,reliabletorquewrench.

(6)Force

Commonsenseshoulddictatehowmuchforceisnecessaryinassemblyanddisassembly.If apartseemsespeciallydifficulttoremoveorinstall,stopandexaminewhatmaybecausingthe problem.Whenevertappingisnecessary,taplightlyusingawoodenorplastic-facedmallet.Use animpactdriverforscrews(particularlyfortheremovingscrewsheldbynon-permanentlocking agent)inordertoavoiddamagingthescrewheads.

(7)Edges

Watchforsharpedges,astheycouldcauseinjurythroughcarelesshandling,especiallyduring majorenginedisassemblyandassembly.Useacleanpieceofthickclothwhenliftingtheengine orturningitover.

(8)HighFlash-PointSolvent

Ahighflash-pointsolventisrecommendedtoreducefiredanger.AcommercialsolventcommonlyavailableinNorthAmericaisstandardsolvent(genericname).Alwaysfollowmanufacturer andcontainerdirectionsregardingtheuseofanysolvent.

(9)Gasket,O-ring

ReplaceagasketoranO-ringwithanewpartwhendisassembling.Removeanyforeignmatter fromthematingsurfaceofthegasketorO-ringtoensureaperfectlysmoothsurfacetoprevent oilorcompressionleaks.

(10)LiquidGasket,LockingAgent

Cleanandpreparesurfaceswhereliquidgasketornon-permanentlockingagentwillbeused. Applythemsparingly.Excessiveamountmayblockengineoilpassagesandcauseseriousdamage.

BeforeServicing

(11)Press

Whenusingapressordrivertoinstallapartsuchasawheelbearing,applyasmallamountof oiltotheareawherethetwopartscomeincontacttoensureasmoothfit.

(12)BallBearingandNeedleBearing

Donotremoveaballbearingoraneedlebearingunlessitisabsolutelynecessary.Replaceany ballorneedlebearingsthatwereremovedwithnewones.Installbearingswiththemanufacturer andsizemarksfacingout,applyingpressureevenlywithasuitabledriver.Applyforceonlytothe endoftheracethatcontactsthepressfitportion,andpressitevenlyoverthebasecomponent.

(13)OilSealandGreaseSeal

Replaceanyoilorgreasesealsthatwereremovedwithnewones,asremovalgenerallydamagesseals.Oilorgreasesealsshouldbepressedintoplaceusingasuitabledriver,applyinga forceuniformlytotheendofsealuntilthefaceofthesealisevenwiththeendofthehole,unless instructedotherwise.Whenpressinginanoilorgreasesealwhichhasmanufacturer’smarks, pressitinwiththemarksfacingout.

(14)Circlip,RetainingRing,andCotterPin

Wheninstallingcirclipsandretainingrings,takecaretocompressorexpandthemonlyenough toinstallthemandnomore.Installthecirclipwithitschamferedsidefacingloadsideaswell.

Replaceanycirclips,retainingrings,andcotterpinsthatwereremovedwithnewones,asremovalweakensanddeformsthem.Ifoldonesarereused,theycouldbecomedetachedwhile themotorcycleisdriven,leadingtoamajorproblem.

(15)Lubrication

Enginewearisgenerallyatitsmaximumwhiletheengineiswarmingupandbeforeallthesliding surfaceshaveanadequatelubricativefilm.Duringassembly,makesuretoapplyoiltoanysliding surfaceorbearingthathasbeencleaned.Oldgreaseordirtyoilcouldhavelostitslubricative qualityandmaycontainforeignparticlesthatactasabrasives;therefore,makesuretowipeitoff andapplyfreshgreaseoroil.Someoilsandgreasesinparticularshouldbeusedonlyincertain applicationsandmaybeharmfulifusedinanapplicationforwhichtheyarenotintended.

(16)DirectionofEngineRotation

Torotatethecrankshaftmanually,makesuretodosointhedirectionofpositiverotation.Positiverotationiscounterclockwiseasviewedfromtheleftsideoftheengine.Tocarryoutproper adjustment,itisfurthermorenecessarytorotatetheengineinthedirectionofpositiverotationas well.

(17)ReplacementParts

ReplacementPartsmustbeKAWASAKIgenuineorrecommendedbyKAWASAKI.Gaskets, O-rings,oilseals,greaseseals,circlips,cotterpinsorself-lockingnutsmustbereplacedwith newoneswheneverdisassembled.

(18)ElectricalLeads

Alltheelectricalleadsareeitherone-colorortwo-color.Atwo-colorleadisidentifiedfirstby theprimarycolorandthenthestripecolor.Forexample,ayellowleadwiththinredstripesis referredtoasa“yellow/red”lead;itwouldbea“red/yellow”leadifthecolorswerereversed. Unlessinstructedotherwise,electricalleadsmustbeconnectedtoleadsofthesamecolor.

Two-ColorElectrical

(19)Inspection

Whenpartshavebeendisassembled,visuallyinspectthesepartsforthefollowingconditions orotherdamage.Ifthereisanydoubtastotheconditionofthem,replacethemwithnewones.

(20)Specifications

Specificationtermsaredefinedasfollows: "Standards"showdimensionsorperformanceswhichbrand-newpartsorsystemshave. "ServiceLimits"indicatetheusablelimits.Ifthemeasurementshowsexcessivewearordeterioratedperformance,replacethedamagedparts.

OverallLength 1580mm 1590mm OverallWidth 690mm(KX65-A1),730mm(KX65-A2) 760mm

OverallHeight 925mm(KX65-A1),935mm(KX65-A2) 955mm

GeneralSpecifications

Items

KX65-A1 ∼ A2 KX65-A3 A6,A6 ∼ AE

Close 91.5°ABDC ← Duaration 183° ←

LubricationSystem (Gasoline:Oil) Petrolmix(32:1) ←

DriveTrain

PrimaryReductionSystem: Type Gear ← ReductionRatio 3.500(77/22) ← ClutchType Wet,multidisc ← Transmission: Type 6-speed,constantmesh,returnshift ← GearRatios: 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) ←

FinalDriveSystem: Type Chaindrive ← ReductionRatio 3.538(46/13) 3.615(47/13) OverallDriveRatio 13.416@Topgear 13.703@Topgear

TransmissionOil: Grade APISG,SH,SJ,SLorSMwithJASOMA, MA1orMA2 ← Viscosity SAE10W-40 ← Capacity 0.5L ←

Frame Type Tubular,semi-doublecradle ← SteeringAngle 40°toeitherside ← Caster(RakeAngle) 26.5° 27° Trail 60mm ←

FrontTire: Size 60/100-1430M ← Type tubetype ←

RearTire: Size 80/100-1241M ← Type tubetype ←

RimSize: Front 14×1.40 ← Rear 12×1.60 ←

FrontSuspension: Type Telescopicfork ← WheelTravel 210mm ←

RearSuspension:

PeriodicMaintenanceChart

Themaintenancemustbedoneinaccordancewiththischarttokeepthemotorcycleingoodrunning condition.

FREQUENCY

OPERATION

After each race(or 2.5hr.)

Clutch-adjust •

Every 3races (or7.5 hr.)

Every 5races (or12.5 hr.)

Clutchandfrictionplates-inspect† • R

Throttlecable-adjust • Sparkplug-clean,gap† • R

Aircleanerelement-clean •

Every 10races (or25 hr.)

As required

Aircleanerelement-replace Whendamaged

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-replace Every2years

Brakecaliperfluidsealanddustseal-replace Every2years

Brakehose-replace Every4years

Brakehoses,connections-inspect† •

Spoketightnessandrimrunout-inspect† •

Drivechain-adjust •

Drivechain-lubricate •

Drivechainwear-inspect† •

Drivechainslipperandguide-replace Whendamaged

Frontfork-inspect/clean •

Frontforkoil-change 1sttimeafter2races,thenevery5races

Nuts,bolts,fasteners-inspect† •

Fuelsystem-clean •

Fuelhose-replace Every5years

OPERATION

FREQUENCY

After each race(or 2.5hr.)

Fuelhoses,connections-inspect† •

Steeringplay-inspect† •

Every 3races (or7.5 hr.)

Every 5races (or12.5 hr.)

Every 10races (or25 hr.)

Steeringstembearing-grease •

Rearsprocket-inspect† •

Generallubrication-perform •

Wheelbearing-inspect† •

SwingarmandUni-Traklinkagepivots-grease •

SwingarmandUni-Traklinkagepivots-inspect† •

As required

TorqueandLockingAgent

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

Whencheckingthetighteningtorqueoftheboltsandnuts,firstloosentheboltornutbyhalfaturn andthentightentospecifiedtorque.

Lettersusedinthe"Remarks"columnmean:

L:Applyanon-permanentlockingagenttothethreads.

Lh:Left-handThreads. R:ReplacementParts S:Tightenthefastenersfollowingthespecifiedsequence.

Fastener

FuelSystem

RearFrameMountingBolts

Torque

N·m kgf·m ft·lb Remarks

34 3.5 25

CarburetorClampScrews 1.5 0.15 13in·lb

CarburetorHolderMountingBolts 8.8 0.90 78in·lb

AirCleanerHousingPlateNuts 3.0 0.31 27in·lb

AirCleanerHousingMountingBolts 8.8 0.90 78in·lb

ReedValveScrews 9.8 1.0 87in·lb

CoolingSystem

RadiatorMountingBolts 8.8 0.90 78in·lb

ShroudMountingBolts 8.8 0.90 78in·lb

AirBleederBolt 8.8 0.90 78in·lb

WaterPumpCoverBolts 8.8 0.90 78in·lb

WaterPumpImpellerBolt 8.3 0.85 73in·lb

WaterHoseClampScrews 1.5 0.15 13in·lb

CoolantDrainPlug(WaterPump) 8.8 0.90 78in·lb

WaterPumpCoverFittingBolts 5.9 0.60 52in·lb

EngineTopEnd

CylinderHeadNuts 25 2.5 18 SparkPlug 26 2.6 19

CylinderNuts 25 2.5 18

MufflerMountingBolts 8.8 0.90 78in·lb L

ExpansionChamberDamperMountingBolt, Nut 8.8 0.90 78in·lb

InnerPipeMountingBolts(KX65A1 A2) 5.9 0.6 52in·lb L

InnerPipeMountingBolts(KX65A3 ) 8.8 0.90 78in·lb L

EngineRightSide

PrimaryGearNut(KX65A6 ∼) 49 5.0 36 Lh

ClutchSpringBolts 9.3 0.95 82in·lb

ClutchHubBolt 64 6.5 47

RatchetGuideBolt 8.8 0.90 78in·lb

RatchetGuideScrew 5.2 0.53 46in·lb

KickPedalBolt 12 1.2 104in·lb

RightEngineCoverBolts 8.8 0.90 78in·lb

OilFillerCap 1.5 0.15 13in·lb