Kawasaki KX65 Motorcycle User Manual

Troubleshooting Guide
Jumps out of gear:
Shift fork worn
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Gear positioning lever spring weak or bro-
Shift fork guide pin worn
Drive shaft, output shaft, and/or gear
splines worn
Gear positioning lever spring weak or bro-
Shift mechanism arm spring broken
Abnormal Engine Noise:
CDI Unit trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
Other noise:
Connecting rod small end clearance exces-
Connecting rod big end clearance exces-
Piston ring worn, broken or stuck
Piston seizure or damaged
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head con-
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Primary gear worn or chipped
Abnormal Drive Train Noise
Clutch noise:
Clutch housing/friction plate clearance ex-
Clutch housing gear/primary gear backlash
Metal chip jammed in clutch housing gear
Transmission noise:
Crankcase bearing worn or damaged
Transmission gear worn or chipped
Metal chip jammed in gear teeth
Transmission oil insufficient or too thin
Kick ratchet gear not properly disengaging
from kick gear
Output shaft idle gear worn or chipped
Drive chain noise:
Drive chain adjusted improperly
Chain worn
Rear and/or engine sprocket(s) worn
Chain lubrication insufficient
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Cylinder damaged
Other noise
Bracket, nut, bolt, etc. not properly
mounted or tightened
Exhaust Smoke:
Excessive white smoke:
Throttle cable maladjusted
Brownish smoke:
Air cleaner clogged
Main jet too large of fallen out
Choke plunger stuck open
Float level too high
Handling and/or Stability
Handlebar hard to turn:
Control Cable routing incorrect
Wiring routing incorrect
Steering stem nut too tight
Bearing ball damaged
Bearing race dented or worn
Steering stem bearing lubrication inade-
Steering stem bent
Tire air pressure too low
Handlebar shakes or excessively vibrates:
Tire worn
Swingarm sleeve or needle bearing dam-
Rim warped, or not balanced
Front, rear axle runout excessive
Wheel bearing worn
Handlebar clamp loose
Steering stem head nut loose
Handlebar pulls to one side:
Frame bent