🏷️ Basic Information

Make:

Kawasaki

Model:

KX65

Years Covered:

2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014

Chassis Codes:

KX65-A1 (2000), KX65-A2 (2001), KX65-A3 (2002), KX65-A4 (2003), KX65-A5 (2004), KX65A6 (2005-2006), KX65A7 (2007), KX65A8 (2008), KX65A9 (2009), KX65AA (2010), KX65AB (2011), KX65AC (2012), KX65AD (2013), KX65AE (2014)

👋 Introduction

Description:

The Kawasaki KX65 is a highly regarded entry-level motocross bike, favored for its potent two-stroke engine, agile handling, and robust construction, making it a popular choice for young riders and aspiring racers. This service manual is essential for maintaining its peak performance.

Competitors:

Key competitors in its class include the KTM 65 SX, Yamaha YZ65, and Suzuki RM65.

Manual Advantage:

Provides detailed, step-by-step repair instructions, enabling owners to perform maintenance and repairs efficiently, saving on labor costs. The digital format offers superior usability with zoom capabilities.

📋 Manual Details

Covered Models:

All Kawasaki KX65 variants from 2000-2014

Type:

Service Repair Manual

Language:

English

Format:

PDF (Instant Download)

📖 Manual Coverage

Engine:

Top End, Right Side, Bottom End/Transmission

Fuel System:

Complete coverage of fuel delivery and carburetor system

Cooling System:

Radiator, hoses, coolant specifications and procedures

Drivetrain:

Final Drive, Wheels and Tires

Brakes:

Front and rear brake system service and repair

Suspension:

Front fork and rear shock absorber service, adjustment, and overhaul

Steering:

Handlebar, triple clamps, and steering bearing service

Electrical:

Ignition system, lighting, wiring diagrams, and component testing

General Maintenance:

Routine checks, lubrication, adjustments, and fluid changes

Engine Rebuild:

Complete engine disassembly, inspection, repair, and reassembly procedures

Troubleshooting:

Diagnostic procedures for common issues and faults

Component Replacement:

Step-by-step guidance for replacing major and minor components

Engine Removal Installation:

Detailed instructions for removing and reinstalling the engine assembly

Depth:

Comprehensive; covers everything from basic maintenance to complete engine and chassis overhauls. Includes detailed specifications, torque values, and diagnostic information.

📊 Manual Specifications

Compatibility:

All Versions of Windows & Mac

Reader Requirement:

Adobe PDF Reader

Digital Clarity:

High clarity, allows zooming for detailed examination of diagrams and text.

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 2-stroke, single-cylinder

Displacement:

64.8 cc

Bore X Stroke:

44.5 x 41.6 mm

Compression Ratio:

8.7:1 (typical, may vary slightly by year)

Horsepower:

Approximately 15.6 hp @ 13,000 rpm (varies by year and tuning)

Torque:

Approximately 7.0 lb-ft @ 11,000 rpm (varies by year and tuning)

Carburetor:

Keihin PWK28 (typical, may vary slightly)

Fuel Type:

Unleaded gasoline with 2-stroke oil mix (100:1 ratio specified by Kawasaki, though 50:1 is common practice)

Ignition System:

Digital CDI

Cooling Method:

Liquid-cooled

Transmission Oil Type:

Kawasaki Genuine Transmission Oil (or equivalent API GL-4, SAE 10W-30)

🔧 Transmission

Type:

6-speed constant mesh

Clutch:

Wet, multi-disc

Gear Ratios:

Detailed gear ratios are available in the manual.

📐 Dimensions

Length:

Approx. 1685 mm (66.3 in)

Width:

Approx. 760 mm (29.9 in)

Height:

Approx. 1045 mm (41.1 in)

Wheelbase:

Approx. 1175 mm (46.3 in)

Dry Weight:

Approx. 60 kg (132 lbs)

Fuel Tank Capacity:

5.5 L (1.45 US gal)

🛡️ Safety Features

Crash Safety:

N/A (Off-road vehicle, safety ratings are not typically applied like road vehicles)

Braking System:

Front and rear disc brakes for effective stopping power.

Frame Construction:

High-tensile steel perimeter frame designed for rigidity and durability.

💡 Technology Features

Features:

N/A (As a dedicated off-road competition machine, it lacks typical infotainment features found on road motorcycles.)

Features:

N/A (Focus is on rider control and mechanical feedback.)

Features:

N/A

🔧 Maintenance

Oil Change:

Refer to manual for specific intervals based on usage; typically after every few riding sessions for optimal engine life.

Air Filter Cleaning:

Frequent cleaning and re-oiling recommended, especially in dusty conditions.

Spark Plug Inspection:

Inspect and clean/replace as needed based on performance and visual inspection. Manual will provide gap and type specifications.

Top End Rebuild:

Recommended every 30-50 hours of racing use, or as indicated by loss of compression or performance issues. Manual provides detailed procedures and wear limits.

Coolant:

Kawasaki Coolant (or equivalent ethylene glycol-based coolant with demineralized water at 50/50 mix)

Brake Fluid:

DOT 3 or DOT 4 brake fluid

Common Wear Items:

Clutch plates, piston rings, crank seals, and suspension seals are common wear items on high-performance 2-stroke motocross bikes of this era.

Carburetor Tuning:

Carburetor jetting may require adjustments based on altitude, temperature, and modifications. Manual details base settings and tuning guidelines.

Overheating:

Can occur with improper coolant levels, airflow obstruction, or high ambient temperatures. Ensuring the cooling system is clean and functional is key.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki has a long-standing reputation for producing high-performance off-road motorcycles, particularly in the KX line, known for their racing heritage and technological advancements.

Kx65 Development:

The KX65 has been a staple in the youth motocross segment since its introduction, consistently offering a potent package for young riders transitioning into competitive racing. Minor updates often focus on graphics and color schemes, with core mechanicals remaining robust.

Manufacturing Location:

Japan (typical for Kawasaki motorcycles)

🏆 Awards & Recognition

Market Perception:

The KX65 is consistently recognized as a leading choice for youth motocross racing, often praised for its performance and durability in its class.