2012 Kawasaki KX65 Owners Manual

2012 Kawasaki KX65 Manual

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  • 2012 Kawasaki KX65 | Owners Manual - Page 1
  • 2012 Kawasaki KX65 | Owners Manual - Page 2
  • 2012 Kawasaki KX65 | Owners Manual - Page 3
    Quick Reference Guide This Quick Reference Guide will assist you in finding the information you're looking for. GENERAL INFORMATION MAINTENANCE AND ADJUSTMENT TROUBLESHOOTING GUIDE TUNING STORAGE j j j j j A Table of Contents is included after the Foreword.
  • 2012 Kawasaki KX65 | Owners Manual - Page 4
    limited to participation in sanctioned competition events upon a closed • The course. vehicle should not be used for general off-load recreation riding. • This Read owner's manual. •
  • 2012 Kawasaki KX65 | Owners Manual - Page 5
    Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. DANGER DANGER
  • 2012 Kawasaki KX65 | Owners Manual - Page 6
    FOR GENERAL OFF-ROAD RECREATIONAL RIDING. READ OWNER'S MANUAL. Motorcycle Noise Emission Control Information This motorcycle is designed sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your service and/or necessary repairs.
  • 2012 Kawasaki KX65 | Owners Manual - Page 7
  • 2012 Kawasaki KX65 | Owners Manual - Page 8
    tuned competition machine for participation in racing events. As with any mechanical device, proper care and maintenance are important for trouble-free operation and top performance. This manual is written to enable you to keep your KX properly tuned and adjusted. Due to improvements in design and
  • 2012 Kawasaki KX65 | Owners Manual - Page 9
    techniques. Read and understand the owner's manual provided with the motorcycle. Review all instructions and warnings with your child. 6. riding the motorcycle. Also, familiarity with the motorcycle is important should a problem occur far from help. 9. Do not allow your child to ride unsupervised
  • 2012 Kawasaki KX65 | Owners Manual - Page 10
    This motorcycle is designed for a rider weighting less than 55 kg (121 ponds). Exceeding this limit could damage the motorcycle.
  • 2012 Kawasaki KX65 | Owners Manual - Page 11
    ...Front Fork ...Rear Suspension (UNI-TRAK®)...Wheels ...Tightening Torques of Nuts and Bolts...Cleaning Your Motorcycle...Lubrication...TROUBLESHOOTING GUIDE...TUNING ...Carburetor Tuning ...Suspension Tuning...Gearing...Special Care According to Track Conditions . OPTIONAL PARTS ...PRE-RACE CHECKS
  • 2012 Kawasaki KX65 | Owners Manual - Page 12
    10 SPECIFICATIONS SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Ground Clearance Curb Mass Fuel Tank Capacity ENGINE Type Bore × Stroke Displacement Compression Ratio: Timing: Intake port: Open Closed Scavenging port: Open Closed Exhaust port: Carburetor Open
  • 2012 Kawasaki KX65 | Owners Manual - Page 13
    SPECIFICATIONS 11 Lubrication System Starting System Ignition System Ignition Timing Spark Plug Spark Plug Terminal TRANSMISSION Transmission Type Clutch Type Drive system Gear Ratios: 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear Primary Reduction Ratio Final Reduction Ratio Overall Ratio (
  • 2012 Kawasaki KX65 | Owners Manual - Page 14
    12 SPECIFICATIONS FRAME Type Steering Angle Castor Trail Tire Size, Type: Rim Size: Front Rear Front Rear Suspension: Front Suspension Travel Rear Wheel Travel Front Fork Oil Type Level (fork compressed, spring removed) BRAKES Type Effective Disc Diameter: (Front & Rear) Front Rear Specifications
  • 2012 Kawasaki KX65 | Owners Manual - Page 15
    GENERAL INFORMATION 13 GENERAL INFORMATION Location of Parts j 1. Clutch Lever 2. Engine Stop Button 3. Fuel Tank Cap 4. Front Brake Fluid Reservoir 5. Front Brake Lever 6. Throttle Grip
  • 2012 Kawasaki KX65 | Owners Manual - Page 16
    14 GENERAL INFORMATION j 7. Front Fork 8. Radiator 9. Fuel Tank 10. Fuel Tap 11. Carburetor 12. Seat 13. Air Cleaner Element 14. Brake Disc 15. Brake Caliper 16. Shift Pedal 17. Rear Shock Absorber 18. Swingarm 19. Chain Guide 20. Drive Chain
  • 2012 Kawasaki KX65 | Owners Manual - Page 17
    GENERAL INFORMATION 15 j 21. Muffler 22. Rear Brake Fluid Reservoir 23. Rear Shock Absorber Gas Reservoir 24. Kick Pedal 25. Rear Brake Pedal 26. Transmission Oil Level Inspection Window 27. Water Pump Cover 28. Exhaust Pipe
  • 2012 Kawasaki KX65 | Owners Manual - Page 18
    16 GENERAL INFORMATION j Side Stand Support the motorcycle with the provided side stand as shown. Fuel The attempt to ride the motorcycle when the side stand is down. NOTE żSupport the motorcycle by using the suitable stand when performing the maintenance or adjustment. A. Fuel Tank Cap
  • 2012 Kawasaki KX65 | Owners Manual - Page 19
    with a minimum Antiknock index of 90. The Antiknock Index is posted on service station pumps in the U.S.A. The octane rating of a gasoline is a standard industry specifications may result in unsatisfactory performance. Operating problems that result from the use of poor quality or nonrecommended
  • 2012 Kawasaki KX65 | Owners Manual - Page 20
    gasohol" containing more than 5% methanol. Fuel system damage and performance problems may result. Gasoline/Ether Blends - The most common ether is fuel from the fuel tank and carburetors. See the Storage section in this manual. Two-Stroke Engine Oil Oil must be mixed with the gasoline to lubricate
  • 2012 Kawasaki KX65 | Owners Manual - Page 21
    GENERAL INFORMATION 19 Recommended Oil żShell Advance Racing X j Kick Pedal This motorcycle starting system is primary kick. When the clutch lever is pulled, the motorcycle can be started with the transmission in any gear. żCastrol A747 Gasoline-Engine Oil Mixing Ratio 32 : 1 (gasoline: engine oil
  • 2012 Kawasaki KX65 | Owners Manual - Page 22
    20 GENERAL INFORMATION j Starting the Engine • Turn the fuel tap lever to the ON position. A. Choke Knob after the engine has started, do not push • Even back the choke knob until the engine is thoroughly warmed up. A. Fuel Tap B. OFF position C. ON position NOTE żWhen the engine is already
  • 2012 Kawasaki KX65 | Owners Manual - Page 23
    GENERAL INFORMATION 21 j Shifting Gears This motorcycle is equipped with a 6-speed "return shift" transmission. The neutral is located halfway between 1st and 2nd gear. "Return shift" means that when shifting up or down, each gear must be engaged before the next higher or lower gear may be selected
  • 2012 Kawasaki KX65 | Owners Manual - Page 24
    22 GENERAL INFORMATION j Stopping the Motorcycle For maximum deceleration, close the throttle and apply both front and rear brakes. Pull in the clutch lever as the motorcycle comes to a stop. Independent use of the front or rear brake may be advantageous in certain circumstances. Shift down
  • 2012 Kawasaki KX65 | Owners Manual - Page 25
    GENERAL INFORMATION 23 4. Break-In A brief break-in procedure must be carried out to obtain the proper operating clearances in the engine and transmission, which are necessary for performance and reliability. 5. 6. NOTICE For the first hour or 20 km (12 mi) of operation, run the engine at low and
  • 2012 Kawasaki KX65 | Owners Manual - Page 26
    is ready for regular operation. Using the proper riding skills and techniques and avoiding recklessly high engine speeds will keep the engine trouble-free. j NOTE żAfter break-in, install a new standard spark plug, and change the transmission oil. żTo keep optimum engine performance, replace the
  • 2012 Kawasaki KX65 | Owners Manual - Page 27
    GENERAL INFORMATION 25 j Daily Pre-Ride Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure a safe, reliable ride. If any irregularities are found during these checks, refer to the appropriate section and
  • 2012 Kawasaki KX65 | Owners Manual - Page 28
    26 GENERAL INFORMATION Muffler ...Engine Sprocket ...Frame Tires ...Spokes ...Drive Chain ...Front and rear brakes ...Throttle ...Steering ...Front Fork ...Rear Shock Absorber ...Fuel Tank ...Rear Sprocket ...Engine stop button ...Nuts, bolts, fasteners ... j żApply oil to air cleaner element żNo
  • 2012 Kawasaki KX65 | Owners Manual - Page 29
    GENERAL INFORMATION 27 j After-Race Checks After racing, first clean the motorcycle (see p. 99), then inspect the entire motorcycle with special attention to the air cleaner, carburetor, brakes, etc. Carry out the general lubrication (see p. 101) and make necessary adjustments.
  • 2012 Kawasaki KX65 | Owners Manual - Page 30
    28 MAINTENANCE AND ADJUSTMENT MAINTENANCE AND ADJUSTMENT Periodic Maintenance Chart The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. FREQUENCY JOB
  • 2012 Kawasaki KX65 | Owners Manual - Page 31
    MAINTENANCE AND ADJUSTMENT 29 FREQUENCY JOB Silencer-clean/check † Silencer packing-change Small end bearing-check † Kick pedal and shift pedal-clean Exhaust pipe O-ring-replace Engine sprocket-check † Coolant-check † Radiator hoses/connections-check † *Reed valve-check† Brake adjustment-check †
  • 2012 Kawasaki KX65 | Owners Manual - Page 32
    AND ADJUSTMENT FREQUENCY JOB Spoke tightness and rim runout-check † Drive chain-adjust Drive chain-lubricate Drive chain wear-check † Chain slipper and guide-replace Front fork-inspect/clean *Front fork oil-change Nuts, bolts/fasteners-check † Fuel system-clean Fuel hose-replace *Brake hoses
  • 2012 Kawasaki KX65 | Owners Manual - Page 33
    (or required 25 hours) See ref. 101 j • • • • - - - - 1st time after 2 races, then every 5 races †: Replace, add, adjust, clean or torque if necessary. R: Replace *: Should be serviced by referring to the Service Manual or an authorized Kawasaki dealer.
  • 2012 Kawasaki KX65 | Owners Manual - Page 34
    32 MAINTENANCE AND ADJUSTMENT Transmission Oil In order for the transmission and clutch to function properly, maintain the transmission oil at the proper level, and change the oil periodically. j the excess oil using a syringe or other suitable device. If the oil level is low, add the correct
  • 2012 Kawasaki KX65 | Owners Manual - Page 35
    MAINTENANCE AND ADJUSTMENT 33 Oil Change The transmission oil should be changed periodically to ensure long engine life. Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily. Stop the engine, and place a container beneath it. Remove the oil filler cap. Remove the
  • 2012 Kawasaki KX65 | Owners Manual - Page 36
    34 MAINTENANCE AND ADJUSTMENT Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. Cooling System Radiator Hoses Check the radiator hoses for cracks or deterioration, and the
  • 2012 Kawasaki KX65 | Owners Manual - Page 37
    MAINTENANCE AND ADJUSTMENT 35 WARNING The cooling system can get extremely hot during normal operation and cause serious burns. Do not touch the radiator when it is hot, nor open the radiator cap. Hot coolant inside will cause severe burns. j NOTE żThe coolant originally filled into the cooling
  • 2012 Kawasaki KX65 | Owners Manual - Page 38
    36 MAINTENANCE AND ADJUSTMENT • Install the radiator cap A. Coolant Level B. Radiator Breather Hose j Coolant Change The coolant should be changed periodically to ensure long engine life. Wait for the engine to cool completely. Lean the motorcycle slightly to the right until the radiator cap is
  • 2012 Kawasaki KX65 | Owners Manual - Page 39
    torques. system must be flushed. NOTICE Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufacture. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the cooling system
  • 2012 Kawasaki KX65 | Owners Manual - Page 40
    38 MAINTENANCE AND ADJUSTMENT żLoosen the air bleeder bolt on the cylinder head j until the coolant begins to flow out the air bleeder bolt hole (that is, until all the remaining air has been forced out). żStart the engine with the radiator cap removed and run it until no more air bubbles can
  • 2012 Kawasaki KX65 | Owners Manual - Page 41
    MAINTENANCE AND ADJUSTMENT 39 Spark Plug If the plug is oily or has carbon built up on it, clean it (preferably with a sandblaster) and then clean off any abrasive particles. The plug may also be cleaned using a high-flash-point solvent and a wire brush or other suitable tool. If the spark plug
  • 2012 Kawasaki KX65 | Owners Manual - Page 42
    40 MAINTENANCE AND ADJUSTMENT Spark Plug Removal and Installation the spark plug cap off the plug before remov• Pull ing the spark plug. a suitable wrench to the spark plug. • Apply Loosen and remove the spark plug. • When reinstalling • specification. the spark plug, torque it to the Spark Plug
  • 2012 Kawasaki KX65 | Owners Manual - Page 43
    MAINTENANCE AND ADJUSTMENT 41 the stator cover and the gasket. • Install Remove the stator cover and gasket. • Loosen the stator screws. • Adjust the timing by shifting the stator position • within the range offered by the three timing marks on the stator. The ignition timing can be adjusted to suit
  • 2012 Kawasaki KX65 | Owners Manual - Page 44
    42 MAINTENANCE AND ADJUSTMENT Air Cleaner A clogged air cleaner restricts the air intake, increases fuel consumption, reduces engine power, and can cause spark plug fouling. Inspect the air intake system, which includes the air filter and air duct to the carburetor, and the duct clamps and
  • 2012 Kawasaki KX65 | Owners Manual - Page 45
    MAINTENANCE AND ADJUSTMENT 43 NOTICE Do not twist or wring the element, as it gets easily torn or damaged. the element. If it is dirty, clean it. Also • Inspect check if the element is in good condition (no tears, hardening or shrinkage). If damaged, replace the element or it will allow dirt into
  • 2012 Kawasaki KX65 | Owners Manual - Page 46
    44 MAINTENANCE AND ADJUSTMENT WARNING Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the element in a well ventilated area, and take care that there is no spark or flame anywhere near the working areas. Do not use gasoline or low-flash point
  • 2012 Kawasaki KX65 | Owners Manual - Page 47
    MAINTENANCE AND ADJUSTMENT 45 Throttle Cable Throttle Cable Adjustment Inspect the throttle grip for smooth operation in all steering positions. Check and adjust the throttle cable in accordance with the Periodic Maintenance Chart. Check that the throttle grip has 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of play
  • 2012 Kawasaki KX65 | Owners Manual - Page 48
    46 MAINTENANCE AND ADJUSTMENT the play is incorrect, pull the rubber boot off the • If upper end of the throttle cable, loosen the locknut on the upper end of the throttle cable and turn the adjuster to obtain the specified play. Then, tighten the locknut. Reinstall the rubber boot. j • A.
  • 2012 Kawasaki KX65 | Owners Manual - Page 49
    MAINTENANCE AND ADJUSTMENT 47 Carburetor Idling Adjustment Idling adjustment is carried out using the air screw and idling adjusting screw. First turn the air screw in until it is lightly seated, then back it out 1 1/2 turns. Start the engine and warm it up thoroughly. Turn the idling adjusting
  • 2012 Kawasaki KX65 | Owners Manual - Page 50
    48 MAINTENANCE AND ADJUSTMENT Clutch Clutch Lever Adjustment Proper clutch lever play is 8 ∼ 13 mm (0.3 ∼ 0.5 in.). Lever play increases with cable stretch and friction plate wear, requiring periodic adjustment. When the clutch lever play is out of specification, first try adjusting it at the
  • 2012 Kawasaki KX65 | Owners Manual - Page 51
    MAINTENANCE AND ADJUSTMENT 49 Friction Plate Removal NOTICE Do not remove the clutch release shaft unless it is absolutely necessary. If the clutch release shaft is removed, the oil seal must be replaced with a new one. • • • Drain the transmission oil and coolant (see the Transmission Oil
  • 2012 Kawasaki KX65 | Owners Manual - Page 52
    50 MAINTENANCE AND ADJUSTMENT the cotter pin, pivot pin and washer from • Remove the rear brake pedal. the brake pedal mounting bolt and take • Remove off the brake pedal and return spring. j A. Rear Brake Pedal Pivot Pin B. Cotter Pin A. Brake Pedal Mounting Bolt B. Brake Pedal Return Spring
  • 2012 Kawasaki KX65 | Owners Manual - Page 53
    MAINTENANCE AND ADJUSTMENT 51 the water pump hose clamp, and pull off • Loosen the lower end of the water pump hose. the water pump cover bolts, and remove • Unscrew the water pump cover and gasket. the impeller bolt, and take out the im• Remove peller and washer. j A. Impeller Bolt B. Impeller A.
  • 2012 Kawasaki KX65 | Owners Manual - Page 54
    52 MAINTENANCE AND ADJUSTMENT the right engine cover mounting bolt after • Remove pulling off the lower end of the coolant hose. the clutch release lever toward the rear, and • Turn remove the right engine cover and gasket. the clutch pusher, and clutch spring plate • Remove pusher. j A. Clutch
  • 2012 Kawasaki KX65 | Owners Manual - Page 55
    friction plates and steel plates as a set. Measure the thickness of the friction and steel plates with vernier calipers. If they have worn past the service limit, replace them with new ones. •
  • 2012 Kawasaki KX65 | Owners Manual - Page 56
    it with a new one. Friction and Steel Plate Warp Friction Plate Maximum 0.2 mm Standard (0.008 in.) Service Limit 0.3 mm (0.012 in.) Steel Plate Standard Maximum 0.15 mm (0.006 in.) j Service Limit 0.3 mm (0.012 in.) A. Thickness B. Friction Plate Friction and Steel Plate Warp Inspection each
  • 2012 Kawasaki KX65 | Owners Manual - Page 57
    MAINTENANCE AND ADJUSTMENT 55 Friction and Steel Plate Installation • • Install all parts in the reverse order of removal. Install the friction plates and steel plates, alternating between the two; be sure to start and finish with a friction plate. the clutch hub, springs and clutch spring •
  • 2012 Kawasaki KX65 | Owners Manual - Page 58
    56 MAINTENANCE AND ADJUSTMENT j A. Apply grease. the clutch release lever toward the rear. • Turn Place new right engine cover gasket in position • with a a thin layer of grease. a high-temperature grease to the kick shaft • Apply oil seal lips and kick shaft spline. the right engine cover to the
  • 2012 Kawasaki KX65 | Owners Manual - Page 59
    MAINTENANCE AND ADJUSTMENT 57 a new water pump cover gasket, and install • Place the water pump cover, and tighten the water pump cover bolt. Water Pump Cover Bolt Tightening Torque 9.4 N·m (0.96 kgf·m, 83 in·lb) the lower end of the water pump hose, • Connect and tighten the clamp screw securely.
  • 2012 Kawasaki KX65 | Owners Manual - Page 60
    58 MAINTENANCE AND ADJUSTMENT Piston Piston Removal the fuel tap lever to the OFF position. • Turn Drain • tion). the coolant (See the Cooling System secthe seat and the left and right side covers. • Remove the left and right radiator covers, and dis• Remove connect the clutch cable (see the Clutch
  • 2012 Kawasaki KX65 | Owners Manual - Page 61
    MAINTENANCE AND ADJUSTMENT 59 the exhaust pipe damper mounting bolts, • Remove and pull the exhaust pipe off toward the front. the exhaust pipe gasket. • Remove Loosen the and pull the carburetor out of • the cylinder clamps, intake joint and air cleaner joint. j A. Exhaust Pipe Damper Mounting
  • 2012 Kawasaki KX65 | Owners Manual - Page 62
    60 MAINTENANCE AND ADJUSTMENT the coolant hose at the cylinder head. • Disconnect Remove the plug. • Remove the spark head nuts, and take off the • cylinder headcylinder and gasket. the cylinder nuts. • Remove Lift off the and remove the cylinder base • gasket. If cylinder, necessary, tap lightly
  • 2012 Kawasaki KX65 | Owners Manual - Page 63
    MAINTENANCE AND ADJUSTMENT 61 a clean cloth into the crankcase opening • Stuff around the connecting rod so that no parts will fall Piston Ring Removal to remove it. • • into the crankcase. Remove one of the piston pin snap rings with needle nose pliers. Push the piston pin out from the side that
  • 2012 Kawasaki KX65 | Owners Manual - Page 64
    snap ring shows weakness or deformation, A. Thickness Gauge Piston Ring/Groove Clearance (Top and Second) 0.02 ∼ 0.06 mm Standard (0.0008 ∼ 0.0024 in.) Service Limit 0.16 mm (0.0063 in.) • replace it. If the piston pin hole groove shows excessive wear, replace the piston. Measure the diameter of
  • 2012 Kawasaki KX65 | Owners Manual - Page 65
    limit, replace the crankshaft assembly. Connecting Rod Small End Inside Diameter 16.002 ∼ 16.013 mm Standard (0.630 ∼ 0.6304 in.) Service Limit 16.05 mm (0.6319 in.) A. B. C. D. Snap Ring Piston Pin Piston Pin Hole Needle Bearing Piston Installation • Check the needle bearing. NOTE żThe rollers
  • 2012 Kawasaki KX65 | Owners Manual - Page 66
    64 MAINTENANCE AND ADJUSTMENT NOTICE Carbon particles can be very abrasive to piston rings. Don't allow such particles to fall onto the cylinder walls. installing the piston ring on the piston, note • When the following: NOTE j żInstall the piston ring so that the pin in the piston ring groove
  • 2012 Kawasaki KX65 | Owners Manual - Page 67
    MAINTENANCE AND ADJUSTMENT 65 2-stroke engine oil to the connecting rod • Apply needle bearing and the piston pin. the piston so that the "IN" mark faces toward • Install the back (intake side) of the engine. a new piston pin snap ring into the side of the • Fit piston so that the snap ring ends do
  • 2012 Kawasaki KX65 | Owners Manual - Page 68
    66 MAINTENANCE AND ADJUSTMENT that the pin in each piston ring groove is • Check between cylinder over each ring, pressing in opposite sides of the piston rings as necessary. Be certain that the piston rings do not slip out of position. out any carbon and clean the cylinder • Scrape head with a high
  • 2012 Kawasaki KX65 | Owners Manual - Page 69
    the carburetor, note the following: • żBeing careful not to bend or otherwise damage the jet needle, align the groove in the throttle valve with the guide pin in the carburetor body. żCheck that the throttle valve goes all the way down into the carburetor body and slides smoothly. żFit the ridge
  • 2012 Kawasaki KX65 | Owners Manual - Page 70
    68 MAINTENANCE AND ADJUSTMENT NOTICE Always keep the hoses free from obstruction, and make sure they do not get pinched by the chain or shock absorber. the fuel tap lever to the ON position, and • Turn check for fuel leakage from the carburetor. the parts removed. • Install the radiator up to the
  • 2012 Kawasaki KX65 | Owners Manual - Page 71
    MAINTENANCE AND ADJUSTMENT 69 j A. Muffler B. Bolts A. Bolts B. Exhaust Pipe the inner pipe bolts of the front end and • Remove rear end of the muffler, and pull out the tail pipe. A. Bolts
  • 2012 Kawasaki KX65 | Owners Manual - Page 72
    70 MAINTENANCE AND ADJUSTMENT off the old muffler packing with the old inner • Pull glass wool, and install the new one. Drive Chain For safety and to prevent excessive wear, the drive chain must be checked, adjusted, and lubricated in accordance with the Periodic Maintenance Chart. If the chain
  • 2012 Kawasaki KX65 | Owners Manual - Page 73
    MAINTENANCE AND ADJUSTMENT 71 For the rear wheel to be properly aligned, the rear end of the left chain adjuster should align with the same swingarm mark that the rear end of the right chain adjuster aligns with. j A. 45 ∼ 55 mm (1.8 ∼ 2.2 in.) addition to checking the slack, rotate the rear • In
  • 2012 Kawasaki KX65 | Owners Manual - Page 74
    72 MAINTENANCE AND ADJUSTMENT WARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. Align the rear wheel using the marks on the swingarm or measuring the distance between the center of the axle and swingarm pivot. both chain adjuster locknuts.
  • 2012 Kawasaki KX65 | Owners Manual - Page 75
    on a straight part of the chain from the center of the 1st pin to the center of the 21st pin. If the length exceeds the service limit, the chain should be replaced. Since overworn sprockets will cause a new chain to wear faster, inspect both the engine and rear sprockets whenever the
  • 2012 Kawasaki KX65 | Owners Manual - Page 76
    74 MAINTENANCE AND ADJUSTMENT Chain Guide Wear Inspection inspect the drive chain guide and replace • Visually it if excessively worn or damaged. j A. Master Link Clip B. Direction of Rotation A. Chain Guide
  • 2012 Kawasaki KX65 | Owners Manual - Page 77
    MAINTENANCE AND ADJUSTMENT 75 Chain Slipper Wear Inspection • Sprocket Wear Inspection Sprocket Tooth Wear Visually inspect the upper and lower chain slippers on the swingarm and replace them if worn or damaged. inspect the sprocket teeth and replace the • Visually sprocket if its teeth are
  • 2012 Kawasaki KX65 | Owners Manual - Page 78
    76 MAINTENANCE AND ADJUSTMENT Chain Lubrication Lubrication of the drive chain is necessary after riding in the rain or mud, or any time the chain appears dry. A heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication. Apply oil
  • 2012 Kawasaki KX65 | Owners Manual - Page 79
    MAINTENANCE AND ADJUSTMENT 77 the clamp bolts to 25 N·m (2.5 kgf·m, 18 • Torque ft·lb), front first, then rear. If the handlebar clamps are correctly installed, there will be no gap at the front and an even gap at the rear of the clamps after torquing the bolts. Brakes Disc and disc pad wear is
  • 2012 Kawasaki KX65 | Owners Manual - Page 80
    78 MAINTENANCE AND ADJUSTMENT Disc Brake Fluid Inspect the brake fluid level in the front and rear reservoirs and change the brake fluid in accordance with the Periodic Maintenance Chart. The brake fluid should also be changed when contaminated with dirt or water. j NOTE żUse only heavy-duty
  • 2012 Kawasaki KX65 | Owners Manual - Page 81
    MAINTENANCE AND ADJUSTMENT 79 Brake Fluid Level Inspection Front Reservoir With the front reservoir positioned horizontally, the brake fluid must always be above the minimum level line. the brake fluid in the front reservoir is below the • If minimum level line, check for fluid leaks in the brake
  • 2012 Kawasaki KX65 | Owners Manual - Page 82
    80 MAINTENANCE AND ADJUSTMENT Rear Reservoir Positioned horizontally, the rear reservoir must always be more than half full. Remove the right side cover. If the amount of brake fluid is insufficient, check for fluid leaks in the brake line and add brake fluid. Brake Pad Wear Inspection Inspect the
  • 2012 Kawasaki KX65 | Owners Manual - Page 83
    MAINTENANCE AND ADJUSTMENT 81 Steering The steering should always be kept adjusted so that the handlebar will turn freely but not have excessive play. Steering Adjustment Steering Inspection check the steering adjustment, raise the front • To wheel off the ground using a jack (special tool). the
  • 2012 Kawasaki KX65 | Owners Manual - Page 84
    82 MAINTENANCE AND ADJUSTMENT Steering Stem Head Nut Tightening Torque 44 N·m (4.5 kgf·m, 33 ft·lb) Lower Clamp Bolt Tightening Torque 29 N·m (3.0 kgf·m, 22 ft·lb) the steering again and readjust it if neces• Check sary. • Tighten the number plate. Front Fork Any of the following front fork
  • 2012 Kawasaki KX65 | Owners Manual - Page 85
    MAINTENANCE AND ADJUSTMENT 83 Rebound Damping Adjustment • This adjustment affects how quickly the fork rebounds. Depending on the model, the fork rebound damping adjuster has 4 positions. The fully seated position (adjuster turned fully clockwise) is the hardest setting. Turning the adjuster 3
  • 2012 Kawasaki KX65 | Owners Manual - Page 86
    top plug, fork spring and fork • Remove spring set. j WARNING The top plugs are under extreme spring pressure and may eject with great force during service. Use care when removing the top plugs. Wear eye and face protection. both top plug O-rings for damage and re• Check place them if necessary
  • 2012 Kawasaki KX65 | Owners Manual - Page 87
    AND ADJUSTMENT 85 compress the front fork fully by pushing • Slowly up the outer tubes using a jack or other suitable a stand or other suitable support under the • Place front wheel. means under the front wheel. the fork in this position, attach the oil level • With gauge (special tool) to
  • 2012 Kawasaki KX65 | Owners Manual - Page 88
    86 MAINTENANCE AND ADJUSTMENT Fork Oil Level Fork Spring K = 2.45 N/mm K = 2.55 N/mm K = 2.65 N/mm K = 2.75 N/mm K = 2.84 N/mm Standard Level 140 mm (5.50 in.) 135 mm (5.30 in.) 132 mm (5.20 in.) 133 mm (5.24 in.) 131 mm (5.16 in.) Adjustable Range 106 ∼ 150 mm (4.17 ∼ 5.9 in.) 101 ∼ 145 mm (3.98 ∼
  • 2012 Kawasaki KX65 | Owners Manual - Page 89
    MAINTENANCE AND ADJUSTMENT 87 Optional Fork Springs Various fork springs are available to achieve suitable front fork action in accordance with the rider's weight and track condition. Harder springs stiffen the fork action and accelerate the rebound damping. Softer springs soften the fork action
  • 2012 Kawasaki KX65 | Owners Manual - Page 90
    88 MAINTENANCE AND ADJUSTMENT Rear Suspension (UNI-TRAK®) This motorcycle's rear suspension system is called "UNI-TRAK®" and consists of a rear shock absorber unit, a swingarm, two lever rods and a lever. The operating characteristics of the UNI-TRAK® suspension are similar to those of the front
  • 2012 Kawasaki KX65 | Owners Manual - Page 91
    MAINTENANCE AND ADJUSTMENT 89 Rebound Damping Adjuster Settings Spring Preload Adjustment up the side stand as shown. • Set Remove the seat and both side covers. • Loosen the intake duct clamp screw. • Remove theair air case bolts. • Remove the rearcleaner frame and air cleaner case. • j A.
  • 2012 Kawasaki KX65 | Owners Manual - Page 92
    90 MAINTENANCE AND ADJUSTMENT j A. Adjusting Nut B. Locknut C. Hook Wrenches (P/No.57001-1101) A. Adjusting Nut Position B. Locknut C. Adjusting Nut standard adjusting nut position from the cen• The ter of the upper mounting hole and the adjustable range is as follows: Rear Shock Absorber Spring
  • 2012 Kawasaki KX65 | Owners Manual - Page 93
    MAINTENANCE AND ADJUSTMENT 91 Optional Rear Shock Absorber Springs Various rear shock absorber springs are available to achieve suitable rear shock absorber action in accordance with the rider's weight and track condition. A harder spring stiffens the shock absorber action and accelerates the
  • 2012 Kawasaki KX65 | Owners Manual - Page 94
    92 MAINTENANCE AND ADJUSTMENT Spokes and Rims The spokes on both wheels must all be securely and evenly tightened and not be allowed to loosen. Unevenly tightened or loose spokes will cause the rim to warp, the nipples and spokes to fatigue more quickly, and the spokes to break. Bead Protector
  • 2012 Kawasaki KX65 | Owners Manual - Page 95
    MAINTENANCE AND ADJUSTMENT 93 Rim Runout Set up a dial gauge on the side of the rim and rotate the wheel to measure its axial runout. The difference between the highest and lowest readings is the amount of runout. Set up the dial gauge on the inner circumference of the rim and rotate the wheel to
  • 2012 Kawasaki KX65 | Owners Manual - Page 96
    94 MAINTENANCE AND ADJUSTMENT j A. Axial Rim Runout Measurement A. Radial Rim Runout Measurement
  • 2012 Kawasaki KX65 | Owners Manual - Page 97
    Bolts 15. Front Fender Bolts 16. Radiator Bolts 17. Engine Mounting Bolt and Nuts 18. Shift Pedal Bolts 19. Side Cover Mounting Bolts 20. Chain Guide Bolts 21. Chain Adjuster Locknut
  • 2012 Kawasaki KX65 | Owners Manual - Page 98
    96 MAINTENANCE AND ADJUSTMENT j 22. Rear Axle Nut 23. Muffler Bolts 24. Rear Shock Absorber Bolt and Nut 25. Rear Brake Reservoir Bolt or Screw 26. Exhaust Pipe Bolt and Nut 27. Steering Stem Head Nut 28. Brake Lever Holder Bolt 29. UNI-TRAK® Lever Rod Bolt 30. UNI-TRAK® Lever Bolt 31. Rear Brake
  • 2012 Kawasaki KX65 | Owners Manual - Page 99
    MAINTENANCE AND ADJUSTMENT 97 Torque Table Tighten all nuts and bolts to the proper torque using an accurate torque wrench. An insufficiently tightened nut or bolt may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider. An overtightened nut or bolt may
  • 2012 Kawasaki KX65 | Owners Manual - Page 100
    98 MAINTENANCE AND ADJUSTMENT Part Name Brake Caliper Bolts Brake Disc Bolts Engine Mounting Nuts Front Axle Front Fork Clamp Bolts Front Fork Top Plug Handlebar Clamp Bolts Pivot Shaft Nut Rear Axle Nut Rear Brake Pedal Pivot Bolt Rear Frame Bolts Rear Shock Absorber Bolt (Top) Rear Shock Absorber
  • 2012 Kawasaki KX65 | Owners Manual - Page 101
    MAINTENANCE AND ADJUSTMENT 99 Cleaning Your Motorcycle General Precautions Frequent and proper care of your Kawasaki motorcycle will enhance its appearance, optimize overall performance, and extend its useful life. Covering your motorcycle with a high quality, breathable motorcycle cover will help
  • 2012 Kawasaki KX65 | Owners Manual - Page 102
    months or as conditions require. Avoid surfaces with "satin" or "flat" finishes. Always use nonabrasive products and apply them according to the instructions on the container. Windshield and Other Plastic Parts After washing use a soft cloth to gently dry plastic parts. When dry, treat the other
  • 2012 Kawasaki KX65 | Owners Manual - Page 103
    MAINTENANCE AND ADJUSTMENT 101 Leather, Vinyl, and Rubber If your motorcycle has leather accessories special care must be taken. Use a leather cleaner/treatment to clean and care for leather accessories. Washing leather parts with detergent and water will damage them, shortening their life. Vinyl
  • 2012 Kawasaki KX65 | Owners Manual - Page 104
    102 MAINTENANCE AND ADJUSTMENT brake pedal • Rear Rear brake • Kick pedal rod joints • Apply an aerosol cable lubricant with a pressure lubricator on all cables: Clutch cable Throttle cable j • • Cable Lubrication • Shift pedal
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    MAINTENANCE AND ADJUSTMENT 103 • • Apply grease to the following points: Upper end of clutch cable Upper end of throttle cable Drive Chain Lubrication Lubricate the drive chain in accordance with the Periodic Maintenance Chart as well as after riding through rain or on wet track, or any time that
  • 2012 Kawasaki KX65 | Owners Manual - Page 106
    /disconnected Stator damaged Wiring shorted or interrupted j does not give every possible cause for each problem listed. It is meant simply as a quick guide to assist you in troubleshooting for some of the more common difficulties. Starting failure or difficulties Fuel does not flow fuel
  • 2012 Kawasaki KX65 | Owners Manual - Page 107
    TROUBLESHOOTING GUIDE 105 head warped • Cylinder Cylinder gasket damaged • Reed valve damaged • Poor low-speed performance Spark weak Spark plug dirty, broken, or gap improperly adjusted Spark
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    106 TROUBLESHOOTING GUIDE tap clogged • Fuel Fuel • line clogged Compression low plug loose • Spark head insufficiently tightened • Cylinder Cylinder nut loose • Cylinder or piston worn • Piston ring worn,
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    TROUBLESHOOTING GUIDE 107 Cooling system component defective Radiator clogged Radiator cap defective Water pump not rotating • • • Clutch operation faulty Clutch not disengaging properly lever play excessive • Clutch
  • 2012 Kawasaki KX65 | Owners Manual - Page 110
    108 TROUBLESHOOTING GUIDE ring worn, broken or stuck • Piston Piston seized or damaged • Cylinder head gasket leaking • Exhaust pipe leaking at cylinder head • Crankshaft runout excessive • Engine mounts
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    TROUBLESHOOTING GUIDE 109 bearing damaged • Roller Steering bearing race dented or worn • Steering stem lubricated • Steering stem inadequately bent • Tire air pressure too low • Handlebar shakes or
  • 2012 Kawasaki KX65 | Owners Manual - Page 112
    of the spark plug, make sure the ignition timing is correct, service the air cleaner element and decarbonize the muffler. If your machine has past and then starts running poorly with the same carburetor settings, the problem is almost certain to be elsewhere; changing the carburetor settings in such
  • 2012 Kawasaki KX65 | Owners Manual - Page 113
    TUNING 111 With pinging or ratting, make sure that the gasoline is fresh and the octane rattling sufficient. You might also try a different brand of high-octane gasoline. Making Adjustments Carburetor tuning is made by replacing or adjusting the main jet, jet needle and pilot jet, which regulate
  • 2012 Kawasaki KX65 | Owners Manual - Page 114
    112 TUNING There are five grooves in the top of the jet needle in which a clip fits. This clip positions the jet needle in the throttle valve relative to the needle jet. Moving the clip down has the effect of pulling the needle further out of the jet; the mixture is thereby enrichened. Moving the
  • 2012 Kawasaki KX65 | Owners Manual - Page 115
    TUNING 113 On the side of the needle jet two figures are stamped: a letter followed by an even number; these figures indicate the relative size of the needle jet. The letter is "N" (leaner) or "O" (richer). The number stands for one of five sizes within each letter's range. The smaller the number is
  • 2012 Kawasaki KX65 | Owners Manual - Page 116
    114 TUNING żIf the spark plug insulator is whitish, the fuel-air mixture is too lean. Increase the main jet size by one step. żIf the spark plug insulator is wet, the fuel-air mixture is too rich. Reduce the main jet size by one step. Tune the carburetor so that the engine delivers satisfactory
  • 2012 Kawasaki KX65 | Owners Manual - Page 117
    TUNING 115 j Correction Factor Applied to the Jet Needle and Air Screw 1.06 ∼ 1.02 1.02 ∼ 0.98 0.98 ∼ 0.94 Correction factor 1.06 or above Jet needle setting lower clip one position same Needle jet two sizes larger one size larger 1/2 turn in same same one size small 1/2 turn out 0.94 or below
  • 2012 Kawasaki KX65 | Owners Manual - Page 118
    116 TUNING Standard Carburetor Settings Throttle Valve Cutaway #1.5 Air Screw Opening Pilot Jet Needle jet Jet Needle Jet Needle Clip Position Main Jet 1 1/2 #25 O-0 5GSP68-3 3 #190 Air Screw the jet needle clip position, needle jet and • Change air screw opening according to the appropriate chart
  • 2012 Kawasaki KX65 | Owners Manual - Page 119
    POSITIONING on the machine. Before changing the suspension settings, test changing your riding posture or position to check whether it is the cause of the problem or not. It is a wise practice to adjust the suspension to suit the rider's strong points. If you are fast in the corners, adjust the
  • 2012 Kawasaki KX65 | Owners Manual - Page 120
    118 TUNING Fork Oil Level Effect on Fork Stroke Troubleshooting Improper Settings Listed below are some symptoms of improper suspension settings and the most likely means of correcting them. The proper settings can be achieved
  • 2012 Kawasaki KX65 | Owners Manual - Page 121
    TUNING 119 Too Soft The front fork dives excessively during braking and deceleration: Fork oil level too low Springs too soft Oil viscosity too high Fork oil deteriorated Rebound damping improperly adjusted Determining the Proper Settings Standard Settings From the factory, the machine is set up for
  • 2012 Kawasaki KX65 | Owners Manual - Page 122
    120 TUNING Suspension Tuning According the Type of Course Many Corners Lower the front end slightly. [Increase the amount of fork tube protrusion above the upper fork clamp by 5 mm (0.2 in.)]. This accelerates steering and enhances turning ability. Fast Course Raise the front end slightly. [Decrease
  • 2012 Kawasaki KX65 | Owners Manual - Page 123
    adjustment procedures, suspension settings may vary depending on the conditions at the track and the rider's preferences. Front and Rear Suspension Troubleshooting Front End Surges Downhill or During Acceleration Out of Corner The front suspension is too soft. Increase the fork oil level by
  • 2012 Kawasaki KX65 | Owners Manual - Page 124
    122 TUNING NOTE żCheck the front and rear suspension compatibility after making any adjustment. Gearing Selection of the Secondary Reduction Ratio (Rear Sprocket) Rear Sprocket Selection According to Course Conditions Fast Course Small Sprocket Many Curves or Hills Sandy or Soft Ground Large
  • 2012 Kawasaki KX65 | Owners Manual - Page 125
    TUNING 123 it is difficult to set the machine so it is best • Since suited for all portions of the circuit, determine which circuit portions will have the greatest effect on lap time, and tune the machine to these portions. Confirm your settings by recording lap times after each change. In this way
  • 2012 Kawasaki KX65 | Owners Manual - Page 126
    124 OPTIONAL PARTS OPTIONAL PARTS Carburetor Jets 170 180 Main Jet 200 210 230 20 Pilot Jet 22.5 27.5 30 Needle Jet Richer O-4 O-2 N-8 Leaner Jet Needle N-6 5GSP69 Wheel Without Tire Front Rear 1.40-14 1.60-21 Rear Front Suspension Spring K = 0.25 kgf/mm K = 0.26 kgf/mm K = 0.27 kgf/mm (Standard) K
  • 2012 Kawasaki KX65 | Owners Manual - Page 127
    the engine, the crankshaft big end will wear excessively. After riding, inspect the crankshaft big end. If the crankshaft big end is worn past the service limit, replace the crankshaft with a new one.
  • 2012 Kawasaki KX65 | Owners Manual - Page 128
    126 PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE Maintenance After Riding in the Rain or on a Muddy Course Apply grease to swingarm and rear suspension pivots. Inspect the drive chain and rear sprocket for wear. Clean the air cleaner element. Check the cylinder and crankshaft big end bearings. Grease
  • 2012 Kawasaki KX65 | Owners Manual - Page 129
    STORAGE 127 STORAGE Before Storage When the motorcycle is to be stored for any length of time, it should be prepared for storage as follows. Clean the entire vehicle thoroughly. Run the engine for about five minutes to warm the oil, then stop it and drain the transmission oil. WARNING Gasoline is
  • 2012 Kawasaki KX65 | Owners Manual - Page 130
    128 STORAGE the motorcycle to keep dust and dirt away • Cover from it. After Storage the plastic bag from the muffler. • Remove Make sure spark plug is tight. • Fill the fuel the tank with fuel. • Check all the points listed in the Daily pre-ride • checks section. • Perform a General Lubrication
  • 2012 Kawasaki KX65 | Owners Manual - Page 131
    ENVIRONMENTAL PROTECTION 129 ENVIRONMENTAL PROTECTION Kawasaki subscribes to the guidelines of Tread Lightly! a program dedicated to protecting the great outdoors through education and fostering responsible enjoyment of public lands. When using your Kawasaki Motorcycle, please follow these Tread
  • 2012 Kawasaki KX65 | Owners Manual - Page 132
    130 WIRING DIAGRAM WIRING DIAGRAM
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