2014 Kawasaki KX65 Owners Manual
2014 Kawasaki KX65 Manual
2014 Kawasaki KX65 manual content summary:
- 2014 Kawasaki KX65 | Owners Manual - Page 1
- 2014 Kawasaki KX65 | Owners Manual - Page 2
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. - 2014 Kawasaki KX65 | Owners Manual - Page 3
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. - 2014 Kawasaki KX65 | Owners Manual - Page 4
below, heed their instructions! Always follow safe FOR GENERAL OFF-ROAD RECREATIONAL RIDING. READ OWNER'S MANUAL. DANGER DANGER indicates a hazardous situation which, if ○NOTE indicates information that may help or guide you in the operation or service of the vehicle. NOTE This motorcycle is - 2014 Kawasaki KX65 | Owners Manual - Page 5
conducted, this sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur. TO PROTECT THE FUTURE OF YOUR - 2014 Kawasaki KX65 | Owners Manual - Page 6
WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. - 2014 Kawasaki KX65 | Owners Manual - Page 7
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 - 2014 Kawasaki KX65 | Owners Manual - Page 8
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 - 2014 Kawasaki KX65 | Owners Manual - Page 9
This motorcycle is designed for a rider weighting less than 55 kg (121 ponds). Exceeding this limit could damage the motorcycle. - 2014 Kawasaki KX65 | Owners Manual - Page 10
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 - 2014 Kawasaki KX65 | Owners Manual - Page 11
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 - 2014 Kawasaki KX65 | Owners Manual - Page 12
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 ( - 2014 Kawasaki KX65 | Owners Manual - Page 13
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 Amount (per fork leg) Level (fork compressed, spring removed) BRAKES Type Effective Disc Diameter: (Front & Rear) Front - 2014 Kawasaki KX65 | Owners Manual - Page 14
GENERAL INFORMATION 13 GENERAL INFORMATION Location of Labels All warning labels which are on your vehicle are repeated here. Read labels on your vehicle and understand them thoroughly. They contain information which is important for your safety and the safety of anyone else who may operate your - 2014 Kawasaki KX65 | Owners Manual - Page 15
14 GENERAL INFORMATION j 2. 3. 4. 5. 6. 7. Radiator Cap Danger Rear Shock Absorber Warning Disclaimer of Warranty Gasoline-Engine Oil Mixing Ratio Noise Emission Control Information Important Information - 2014 Kawasaki KX65 | Owners Manual - Page 16
GENERAL INFORMATION 15 1) 3) j 2) 4) - 2014 Kawasaki KX65 | Owners Manual - Page 17
16 GENERAL INFORMATION 5) 7) j 6) - 2014 Kawasaki KX65 | Owners Manual - Page 18
GENERAL INFORMATION 17 j Location of Parts 1. Clutch Lever 2. Engine Stop Button 3. Fuel Tank Cap 4. Front Brake Fluid Reservoir 5. Front Brake Lever 6. Throttle Grip - 2014 Kawasaki KX65 | Owners Manual - Page 19
18 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 - 2014 Kawasaki KX65 | Owners Manual - Page 20
GENERAL INFORMATION 19 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 - 2014 Kawasaki KX65 | Owners Manual - Page 21
20 GENERAL INFORMATION j Side Stand Support the motorcycle with the provided side stand as shown. Fuel The engine or attempt to ride the motorcycle when the side stand is down. ○Support the motorcycle by using the suitable stand when performing the maintenance or adjustment. NOTE A. Fuel Tank - 2014 Kawasaki KX65 | Owners Manual - Page 22
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 - 2014 Kawasaki KX65 | Owners Manual - Page 23
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 - 2014 Kawasaki KX65 | Owners Manual - Page 24
*Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds warranty and service requirements and can help to extend the life of your Kawasaki. Gasoline-Engine Oil Mixing Ratio 32 : 1 (gasoline: engine oil) A 32-to - 2014 Kawasaki KX65 | Owners Manual - Page 25
24 GENERAL INFORMATION 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. Starting the Engine • Turn the fuel tap lever to the ON position. A. Kick Pedal A. Fuel Tap B. OFF position C. - 2014 Kawasaki KX65 | Owners Manual - Page 26
GENERAL INFORMATION 25 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 - 2014 Kawasaki KX65 | Owners Manual - Page 27
26 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 - 2014 Kawasaki KX65 | Owners Manual - Page 28
GENERAL INFORMATION 27 j Stopping the Engine the transmission into the neutral position. • Shift After racing the engine slightly, close the throttle • completely and push the engine stop button. Break-In A brief break-in procedure must be carried out to obtain the proper operating clearances in - 2014 Kawasaki KX65 | Owners Manual - Page 29
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 5. 6. Cylinder: ○After break-in, install a new standard spark plug, and change the transmission oil. ○To keep optimum engine performance - 2014 Kawasaki KX65 | Owners Manual - Page 30
GENERAL INFORMATION 29 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 - 2014 Kawasaki KX65 | Owners Manual - Page 31
30 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 ...oil to air cleaner element •Apply damage • - 2014 Kawasaki KX65 | Owners Manual - Page 32
GENERAL INFORMATION 31 j After-Race Checks After racing, first clean the motorcycle (see p. 103), then inspect the entire motorcycle with special attention to the air cleaner, carburetor, brakes, etc. Carry out the general lubrication (see p. 105) and make necessary adjustments. - 2014 Kawasaki KX65 | Owners Manual - Page 33
32 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 - 2014 Kawasaki KX65 | Owners Manual - Page 34
MAINTENANCE AND ADJUSTMENT 33 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 † - 2014 Kawasaki KX65 | Owners Manual - Page 35
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 - 2014 Kawasaki KX65 | Owners Manual - Page 36
(or required 25 hours) See ref. 105 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. - 2014 Kawasaki KX65 | Owners Manual - Page 37
36 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 level is too high, remove the excess oil using a syringe or other suitable device. If the oil level - 2014 Kawasaki KX65 | Owners Manual - Page 38
: SAE10W-40 *Kawasaki Performance Oils and Lubricants have been specifically engineered for your vehicle. Consistent use of these products meets or exceeds service requirements and can help to extend the life of your Kawasaki. j WARNING Transmission oil is a toxic substance. Dispose of used oil - 2014 Kawasaki KX65 | Owners Manual - Page 39
38 MAINTENANCE AND ADJUSTMENT Transmission Oil Total Amount 0.5 L (0.53 US qt) 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 Check the radiator hoses for - 2014 Kawasaki KX65 | Owners Manual - Page 40
MAINTENANCE AND ADJUSTMENT 39 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 ○The coolant originally filled into the cooling sys- - 2014 Kawasaki KX65 | Owners Manual - Page 41
40 MAINTENANCE AND ADJUSTMENT • Install the radiator cap. 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 level to the ground. Remove the radiator cap in - 2014 Kawasaki KX65 | Owners Manual - Page 42
air accumulated in the radiator. 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 - 2014 Kawasaki KX65 | Owners Manual - Page 43
42 MAINTENANCE AND ADJUSTMENT the air bleeder bolt on the cylinder head • Loosen until the coolant begins to flow out the air bleeder bolt hole (that is, until all the remaining air has been forced out). the cooling hoses to force out any air bubbles • Tap caught inside. j A. Air Bubbles A. Air - 2014 Kawasaki KX65 | Owners Manual - Page 44
MAINTENANCE AND ADJUSTMENT 43 Spark Plug If the plug is oily or has carbon built up on it, clean it. The plug may also be cleaned using a high flash -point solvent and a nonmetal brush (nylon etc.). If the spark plug electrodes are corroded, or damaged, or if the insulator is cracked, replace the - 2014 Kawasaki KX65 | Owners Manual - Page 45
44 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 - 2014 Kawasaki KX65 | Owners Manual - Page 46
MAINTENANCE AND ADJUSTMENT 45 the magneto cover and the gasket. • Install the magneto cover and gasket. • Remove Loosen the stator screws. • Adjust the timing by shifting the stator position • within the range offered by the three timing marks ○For best engine performance, it is very important to - 2014 Kawasaki KX65 | Owners Manual - Page 47
46 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 - 2014 Kawasaki KX65 | Owners Manual - Page 48
MAINTENANCE AND ADJUSTMENT 47 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, j hardening or shrinkage). If damaged, replace the element or it will allow dirt - 2014 Kawasaki KX65 | Owners Manual - Page 49
48 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 - 2014 Kawasaki KX65 | Owners Manual - Page 50
MAINTENANCE AND ADJUSTMENT 49 Throttle Cable 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 and turns smoothly. - 2014 Kawasaki KX65 | Owners Manual - Page 51
50 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. - 2014 Kawasaki KX65 | Owners Manual - Page 52
MAINTENANCE AND ADJUSTMENT 51 Carburetor 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 screw to obtain the - 2014 Kawasaki KX65 | Owners Manual - Page 53
52 MAINTENANCE AND ADJUSTMENT Clutch 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 clutch lever as follows. - 2014 Kawasaki KX65 | Owners Manual - Page 54
MAINTENANCE AND ADJUSTMENT 53 Friction Plate Removal the transmission oil and coolant (see the • Drain Transmission Oil section and Cooling System sec- 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 - 2014 Kawasaki KX65 | Owners Manual - Page 55
54 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 - 2014 Kawasaki KX65 | Owners Manual - Page 56
MAINTENANCE AND ADJUSTMENT 55 the water pump hose clamp, and discon• Loosen nect 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 - 2014 Kawasaki KX65 | Owners Manual - Page 57
56 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 - 2014 Kawasaki KX65 | Owners Manual - Page 58
• If friction plates and steel plates as a set. the thickness of the friction and steel • Measure plates with vernier calipers. they have worn past the service limit, replace • If them with new ones. - 2014 Kawasaki KX65 | Owners Manual - Page 59
with a new one. j • 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.) Service Limit 0.3 mm (0.012 in.) A. Thickness B. Friction Plate Friction and Steel Plate Warp Inspection each - 2014 Kawasaki KX65 | Owners Manual - Page 60
MAINTENANCE AND ADJUSTMENT 59 Friction and Steel Plate Installation all parts in the reverse order of removal. • Install Install the friction plates and steel plates, alternat• ing between the two; be sure to start and finish with a friction plate. the clutch hub, springs and clutch spring • - 2014 Kawasaki KX65 | Owners Manual - Page 61
60 MAINTENANCE AND ADJUSTMENT j A. Apply grease. the clutch release lever toward the rear. • Turn a new right engine cover gasket in position • Place with 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 - 2014 Kawasaki KX65 | Owners Manual - Page 62
MAINTENANCE AND ADJUSTMENT 61 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. - 2014 Kawasaki KX65 | Owners Manual - Page 63
62 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 Remove the left and right radiator covers, and dis• connect the clutch cable (see the Clutch - 2014 Kawasaki KX65 | Owners Manual - Page 64
MAINTENANCE AND ADJUSTMENT 63 the exhaust pipe damper mounting bolts, • Remove and pull the exhaust pipe off toward the front. the exhaust pipe gasket. • Remove the clamp screws and pull the carburetor • Loosen out of the cylinder intake joint and air cleaner joint. j A. Exhaust Pipe Damper - 2014 Kawasaki KX65 | Owners Manual - Page 65
64 MAINTENANCE AND ADJUSTMENT the coolant hose at the cylinder head. • Disconnect the spark plug. • Remove the cylinder head nuts, and take off the • Remove cylinder head and gasket. the cylinder nuts. • Remove off the cylinder, and remove the cylinder base • Lift gasket. If necessary, tap lightly - 2014 Kawasaki KX65 | Owners Manual - Page 66
MAINTENANCE AND ADJUSTMENT 65 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 - 2014 Kawasaki KX65 | Owners Manual - Page 67
(Top and Second) 0.97 ∼ 0.99 mm Standard (0.0382 ∼ 0.0390 in.) Service Limit 0.90 mm (0.0354 in.) Piston Ring Groove Width (Top and Second) 1.01 a mi• Measure crometer. the piston pin diameter is less than the service • If limit at any point, replace the piston pin. Piston Pin Diameter 11.995 ∼ - 2014 Kawasaki KX65 | Owners Manual - Page 68
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 • Check the needle bearing. Piston Installation ○The rollers - 2014 Kawasaki KX65 | Owners Manual - Page 69
68 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: fit one end of the piston ring against the pin in • First the ring groove, - 2014 Kawasaki KX65 | Owners Manual - Page 70
MAINTENANCE AND ADJUSTMENT 69 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 - 2014 Kawasaki KX65 | Owners Manual - Page 71
70 MAINTENANCE AND ADJUSTMENT certain that the piston rings do not slip out of position. out any carbon and clean the cylinder • Scrape head with a high flash-point solvent. for mineral deposits and rust in the cylinder • Check head water jacket, and remove them if necessary. the cylinder head - 2014 Kawasaki KX65 | Owners Manual - Page 72
carburetor, note the following: • Being careful notthe to bend or otherwise damage the • jet needle, align the groove in the throttle valve with the guide pin in the carburetor body. that the throttle valve goes all the way down • Check into the carburetor body and slides smoothly. the ridge on - 2014 Kawasaki KX65 | Owners Manual - Page 73
72 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 Fill the radiator up to - 2014 Kawasaki KX65 | Owners Manual - Page 74
MAINTENANCE AND ADJUSTMENT 73 j A. Muffler B. Bolts A. Bolts B. Muffler Pipe the inner pipe bolts of the front end and • Remove rear end of the muffler, and pull out the tail pipe. A. Bolts - 2014 Kawasaki KX65 | Owners Manual - Page 75
74 MAINTENANCE AND ADJUSTMENT off the old silencer wool, and install the new • Pull 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 becomes badly worn or maladjusted- - 2014 Kawasaki KX65 | Owners Manual - Page 76
MAINTENANCE AND ADJUSTMENT 75 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 - 2014 Kawasaki KX65 | Owners Manual - Page 77
76 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. - 2014 Kawasaki KX65 | Owners Manual - Page 78
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 - 2014 Kawasaki KX65 | Owners Manual - Page 79
78 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 - 2014 Kawasaki KX65 | Owners Manual - Page 80
MAINTENANCE AND ADJUSTMENT 79 Chain Slipper Wear Inspection aged. inspect the upper and lower chain slippers • Visually on the swingarm and replace them if worn or dam- Sprocket Wear Inspection Sprocket Tooth Wear inspect the sprocket teeth and replace the • Visually sprocket if its teeth are - 2014 Kawasaki KX65 | Owners Manual - Page 81
80 MAINTENANCE AND ADJUSTMENT Lubrication of the drive chain is necessary after riding in the rain or mud, or any time the chain appears dry with a high quality lubricant for drive chains. Apply lubricant to the side of the rollers so that it will penetrate to the rollers and bushings. Wipe off any - 2014 Kawasaki KX65 | Owners Manual - Page 82
MAINTENANCE AND ADJUSTMENT 81 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 - 2014 Kawasaki KX65 | Owners Manual - Page 83
82 MAINTENANCE AND ADJUSTMENT 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. Use only heavy-duty brake fluid as follows. Front - 2014 Kawasaki KX65 | Owners Manual - Page 84
MAINTENANCE AND ADJUSTMENT 83 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 - 2014 Kawasaki KX65 | Owners Manual - Page 85
84 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 - 2014 Kawasaki KX65 | Owners Manual - Page 86
MAINTENANCE AND ADJUSTMENT 85 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 - 2014 Kawasaki KX65 | Owners Manual - Page 87
86 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 j NOTICE Sticking muds or dusts on - 2014 Kawasaki KX65 | Owners Manual - Page 88
MAINTENANCE AND ADJUSTMENT 87 is fully compressed. Make this adjustment in 10 mm (0.4 in.) steps. 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 - 2014 Kawasaki KX65 | Owners Manual - Page 89
set. A. Top Plug B. Fork Spring C. Fork Spring Seat 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. compress the front fork fully by pushing • Slowly up the outer tubes using - 2014 Kawasaki KX65 | Owners Manual - Page 90
MAINTENANCE AND ADJUSTMENT 89 the fork in this position, attach the oil level • With gauge (special tool) to the top of the fork tube, and measure the distance from the top of the inner tube to the oil level. j A. Outer Tube B. Stand A. Oil Level Gauge (P/No. 57001-1290) the fork oil level as - 2014 Kawasaki KX65 | Owners Manual - Page 91
90 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 ∼ - 2014 Kawasaki KX65 | Owners Manual - Page 92
MAINTENANCE AND ADJUSTMENT 91 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 and slow down the rebound - 2014 Kawasaki KX65 | Owners Manual - Page 93
92 MAINTENANCE AND ADJUSTMENT Rear Suspension (UNI-TRAK®) of the rear shock absorber with a flat-head screwdriver. j NOTICE Sticking muds or dusts on the sliding surface of the rear shock absorber could damage to the oil seal, leading to an oil leak. Clean the sliding surface after each ride. - 2014 Kawasaki KX65 | Owners Manual - Page 94
MAINTENANCE AND ADJUSTMENT 93 Rebound Damping Adjuster Settings Spring Preload Adjustment up the side stand. • Set the seat and both side covers. • Remove Loosen the intake duct clamp screw. • Remove theair air case bolts. • Remove the rearcleaner frame and air cleaner case. • j A. Seated - 2014 Kawasaki KX65 | Owners Manual - Page 95
94 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 - 2014 Kawasaki KX65 | Owners Manual - Page 96
MAINTENANCE AND ADJUSTMENT 95 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 rebound damping. A softer spring softens - 2014 Kawasaki KX65 | Owners Manual - Page 97
96 MAINTENANCE AND ADJUSTMENT 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. Spokes and Rims j There is a bead - 2014 Kawasaki KX65 | Owners Manual - Page 98
MAINTENANCE AND ADJUSTMENT 97 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 measure its - 2014 Kawasaki KX65 | Owners Manual - Page 99
98 MAINTENANCE AND ADJUSTMENT j A. Axial Rim Runout Measurement A. Radial Rim Runout Measurement - 2014 Kawasaki KX65 | Owners Manual - Page 100
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 - 2014 Kawasaki KX65 | Owners Manual - Page 101
100 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. Expansion Chamber Damper Mounting Bolt and Nut 27. Steering Stem Head Nut 28. Brake Lever Holder Bolt 29. UNI-TRAK® Tie-rod Mounting Nuts 30. UNI- - 2014 Kawasaki KX65 | Owners Manual - Page 102
MAINTENANCE AND ADJUSTMENT 101 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 - 2014 Kawasaki KX65 | Owners Manual - Page 103
102 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 Swingarm Pivot Shaft Nut Rear Axle Nut Rear Brake Pedal Mounting Bolt Rear Frame Bolts Rear Shock Absorber Bolt (Top) Rear - 2014 Kawasaki KX65 | Owners Manual - Page 104
such as ammo- j WARNING Build-up of debris or flammable material in and around the vehicle chassis, engine, and exhaust can cause mechanical problems and increase the risk of fire. When operating the vehicle in conditions that allow debris or flammable material to collect in and around the - 2014 Kawasaki KX65 | Owners Manual - Page 105
three 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. After washing use a soft cloth to gently dry plastic parts. When dry, treat the other non-painted plastic parts with - 2014 Kawasaki KX65 | Owners Manual - Page 106
MAINTENANCE AND ADJUSTMENT 105 aluminum should be washed with mild neutral detergent and finished with a spray polish. Aluminum wheels, both painted and unpainted can be cleaned with special non-acid based wheel spray cleaners. If your motorcycle has leather accessories special care must be taken. - 2014 Kawasaki KX65 | Owners Manual - Page 107
106 MAINTENANCE AND ADJUSTMENT brake pedal • Rear brake rod joints • Rear • Kick pedal Apply an aerosol cable lubricant with a pressure lubricator on all cables: Clutch cable Throttle cable j • • Cable Lubrication - 2014 Kawasaki KX65 | Owners Manual - Page 108
MAINTENANCE AND ADJUSTMENT 107 end of clutch cable • Upper Upper end of throttle cable • Apply grease to the following points: lubricant to the sides of the rollers so that it • Apply will penetrate to the rollers and bushings. • Wipe off any excess lubricant. j A. Grease. Lubricate the drive - 2014 Kawasaki KX65 | Owners Manual - Page 109
108 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE ○This troubleshooting guide is not exhaustive and 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 - 2014 Kawasaki KX65 | Owners Manual - Page 110
TROUBLESHOOTING GUIDE 109 head warped • Cylinder gasket damaged • Cylinder • Reed valve damaged Poor low-speed performance plug dirty, broken, or gap improperly ad• Spark justed plug cap - 2014 Kawasaki KX65 | Owners Manual - Page 111
110 TROUBLESHOOTING GUIDE tap clogged • Fuel • Fuel line clogged Compression low plug loose • Spark Cylinder insufficiently tightened • Cylinder head nut loose • Cylinder or piston worn • Piston ring worn, - 2014 Kawasaki KX65 | Owners Manual - Page 112
TROUBLESHOOTING GUIDE 111 Cooling system component defective Radiator clogged Radiator cap defective Water pump not rotating • • • Clutch operation faulty Clutch slipping No clutch lever play Clutch cable - 2014 Kawasaki KX65 | Owners Manual - Page 113
112 TROUBLESHOOTING GUIDE ring worn, broken or stuck • Piston seized or damaged • Piston Cylinder head gasket leaking • Exhaust pipe leaking at cylinder head • Crankshaft runout excessive • Engine mounts - 2014 Kawasaki KX65 | Owners Manual - Page 114
TROUBLESHOOTING GUIDE 113 stem bent • Steering • Tire air pressure too low Handlebar shakes or vibrates excessively worn • Tire Swingarm sleeve or needle bearing damaged • Rim warped out - 2014 Kawasaki KX65 | Owners Manual - Page 115
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 - 2014 Kawasaki KX65 | Owners Manual - Page 116
TUNING 115 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. Carburetor tuning is made by replacing or adjusting the main jet, jet needle and pilot jet, which regulate the fuel flow, and the - 2014 Kawasaki KX65 | Owners Manual - Page 117
116 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 - 2014 Kawasaki KX65 | Owners Manual - Page 118
TUNING 117 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 - 2014 Kawasaki KX65 | Owners Manual - Page 119
118 TUNING the spark plug insulator is whitish, the fuel-air • If mixture is too lean. Increase the main jet size by • • one step. If 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 - 2014 Kawasaki KX65 | Owners Manual - Page 120
TUNING 119 j Correction Factor Applied to the Jet Needle and Air Screw Correction factor 1.06 or above 1.06 ∼ 1.02 1.02 ∼ 0.98 0.98 ∼ 0.94 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 - 2014 Kawasaki KX65 | Owners Manual - Page 121
120 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 - 2014 Kawasaki KX65 | Owners Manual - Page 122
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 - 2014 Kawasaki KX65 | Owners Manual - Page 123
Level Adjustment Adjust the front fork oil level (see Fork oil level adjustment under Front suspension in the Maintenance and Adjustment chapter). Troubleshooting Improper Settings j • • • Suspension stiffens at the end of the fork stroke • Fork oil level too high Spring OK, but suspension too - 2014 Kawasaki KX65 | Owners Manual - Page 124
TUNING 123 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 - 2014 Kawasaki KX65 | Owners Manual - Page 125
124 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 - 2014 Kawasaki KX65 | Owners Manual - Page 126
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 - 2014 Kawasaki KX65 | Owners Manual - Page 127
126 TUNING ○Check the front and rear suspension compatibility after making any adjustment. NOTE 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 - 2014 Kawasaki KX65 | Owners Manual - Page 128
TUNING 127 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 - 2014 Kawasaki KX65 | Owners Manual - Page 129
128 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 Rear Front Rear Sprocket 45T 46T 47T (Standard) 48T 49T Suspension Spring K = 0.25 kgf/mm K = 0.26 kgf/mm K = 0.27 kgf/mm (Standard) K - 2014 Kawasaki KX65 | Owners Manual - Page 130
engine, the crankshaft • If 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. Clean the sliding surface of the front fork and rear shock absorber. • - 2014 Kawasaki KX65 | Owners Manual - Page 131
130 PRE-RACE CHECKS AND AFTER-RACE MAINTENANCE Maintenance After Riding in the Rain or on a Muddy Course Clean the sliding surface of the front fork and rear shock absorber. Apply grease to swingarm and rear suspension pivots. Inspect the drive chain and rear sprocket for wear. Clean the air cleaner - 2014 Kawasaki KX65 | Owners Manual - Page 132
STORAGE 131 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 - 2014 Kawasaki KX65 | Owners Manual - Page 133
132 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 • checks section.points listed in the Daily pre-ride • Perform a General Lubrication - 2014 Kawasaki KX65 | Owners Manual - Page 134
ENVIRONMENTAL PROTECTION 133 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 - 2014 Kawasaki KX65 | Owners Manual - Page 135
134 WIRING DIAGRAM WIRING DIAGRAM - 2014 Kawasaki KX65 | Owners Manual - Page 136
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