Kawasaki KX65 Motorcycle User Manual

Front F ork
Front Fork A ssembly (each fork)
Assembly is the reverse of disassembly.
Replace the following parts removed with a new one.
Guide Bushes
Oil Seal
Bottom Allen Bolt Gasket
Inspect the following and replace them with new ones if
Inner Tube (see Inner Tube Inspection)
Insert the cylinder unit and spring in the inner tube.
Insert the cylinder base [A] in the cylinder unit [B].
The cylinder base must be installed with the tapered side
facing upward.
Install the cylinder unit in the inner tube and the cylinder
base in the bottom of the outer tube.
Apply a non-permanent locking agent to the bottom A llen
bolt and tighten it to the specified torque, using the front
fork cylinder holder.
Torque - Fork Bottom Allen Bolts: 20 N·m (2.0 kgf·m, 14
Special Tools - Fork Cylinder Holder Handle: 57001-183
(use for KX65-A1 A2)
Fork Cylinder Holder A dapter: 57001-1011
(use for KX65-A1 A2)
Install the guide bush [A] (with a used guide bush [B] on
it) by tapping [C] the used guide bush with the fork oil seal
driver [D] until it stops.
Special Tool - Fork Oil Seal Driver: 57001-1219
Install the following.
Oil Seal (use the fork oil seal driver: 57001-1219, the
marked side upward)
Retaining Ring
Dust Seal
Measure the both diameters of the fork s pring ends and
insert the fork spring with the small diameter [A] facing
Pour the fork oil (see Fork Oil change).
Install the front fork (see Front Fork Installation).