2022 Kawasaki KX65 TROUBLESHOOTING GUIDE Owners Manual

2022 Kawasaki KX65 TROUBLESHOOTING GUIDE

TROUBLESHOOTING GUIDE

 

NOTE

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 difficulties

The engine does not turn over

• Cylinder or piston seized
• Crankshaft seized
• Connecting rod small end seized
• Connecting rod big end seized
• Transmission gear or bearing seized
• Kick shaft return spring broken
• Kick ratchet gear not engaging

Fuel does not flow

• No fuel in the tank
• The fuel tap turned off
• Tank cap air vent obstructed
• Fuel tap clogged
• Fuel line clogged
• Float valve clogged

Engine flooded

• Fuel level too high
• The float valve is worn or stuck open
• Wrong starting technique (when the engine is flooded, kick with the throttle fully open to allow more air to reach the engine).

Spark missing or weak

• Spark plug dirty, broken, or gap improperly adjusted
• Spark plug cap or high-tension wiring defective
• Spark plug cap not contacting properly
• Spark plug type Incorrect
• igniter defective
• Ignition coil defective
• Ignition coil resistor defective/disconnected
• Stator damaged
• Wiring shorted or interrupted

Fuel-air mixture incorrect

• Idling adjusting screw improperly adjusted
• Pilot jet or air passage clogged
• Air cleaner element clogged, poorly sealed, or not installed
• Starter jet clogged

Compression low

• Spark plug lose
• The cylinder head was insufficiently tightened
• Cylinder nut lose
• Cylinder or piston worn
• Piston ring worn, weak, broken, or sticking
• Piston ring side clearance excessive
• Cylinder head gasket damaged
• Cylinder head warped
• Cylinder gasket damaged
• Reed valve damaged

Poor low-speed performance

Spark weak

• Spark plug dirty, broken, or gap improperly adjusted
• Spark plug cap or high-tension wiring defective
• Spark plug cap shorted or not contacting properly
• Spark plug type Incorrect
• Igniter defective
• Ignition coil defective
• Stator damaged

Fuel-air mixture incorrect

• Idling adjusting screw improperly adjusted
• Pilot jet or air passage clogged
• Air cleaner element clogged, poorly sealed, or not installed
• Starter plunger stuck open
• Carburetor fuel level too high or too low
• The fuel tank air vent obstructed
• Carburetor holder lose
• Air intake duct lose

Compression low

• Spark plug lose
• The cylinder head was insufficiently tightened
• Cylinder nut lose
• Cylinder or piston worn
• Piston ring worn, weak, broken, or sticking
• Piston ring side clearance excessive
• Cylinder head gasket damaged
• Cylinder head warped
• Cylinder gasket damaged
• Reed valve damaged

Other

• Igniter defective
• Transmission oil viscosity is too high
• Brake dragging

Poor or no high-speed performance

Firing incorrect

• Spark plug dirty, damaged, or gap improperly adjusted
• Spark plug cap or high-tension wiring defective
• Spark plug cap shorted or not contacting properly
• Spark plug type Incorrect
• Igniter defective
• Ignition coil defective
• Stator damaged

Fuel-air mixture incorrect

• The main jet is clogged or the wrong size
• Jet needle or needle jet worn
• Jet needle clip in the wrong position
• Carburetor fuel level too high or too low
• Air jet or air passage clogged
• Air cleaner element clogged, poorly sealed, or not installed
• Starter plunger stuck open
• Fuel supply to carburetor insufficient
• Fuel contaminated with water or foreign matter
• The fuel tank air vent obstructed
• Carburetor holder lose
• Air intake duct lose
• Fuel tap clogged
• Fuel line clogged

Compression low

• Spark plug loose
• The cylinder head was insufficiently tightened
• Cylinder nut loose
• Cylinder or piston worn
• Piston ring worn, weak, broken, or sticking
• Piston ring side clearance excessive
• Cylinder head gasket damaged
• Cylinder head warped
• Cylinder gasket damaged
• Reed valve damaged

Improper acceleration

• Starter plunger stuck open
• Carburetor fuel level too high or too low
• The main jet clogged
• The throttle valve does not fully open
• Air cleaner element clogged
• Muffler clogged
• Fuel contaminated with water or foreign matter
• The cylinder exhaust port clogged
• Brake dragging
• Clutch slipping
• Engine overheating
• Transmission oil level too high
• Transmission oil viscosity is too high
• Crankshaft bearing is worn or damaged

Knocking

• Carbon built up in combustion chamber
• Fuel quality poor or type incorrect
• Spark plug type Incorrect
• Igniter defective

Engine overheating

Firing incorrect

• Spark plug dirty, broken, or gap improperly adjusted
• Spark plug type Incorrect
• Igniter defective

Fuel-air mixture incorrect

• The main jet is clogged or the wrong size
• Carburetor fuel level too low
• Carburetor holder lose
• Air cleaner element clogged, poorly sealed, or not installed
• The air intake duct is poorly sealed

Compression high

• Carbon built up in combustion chamber

Engine overloaded

• Brake dragging
• Clutch slipping
• Transmission oil level too high
• Transmission oil viscosity too high

Lubrication inadequate

• Transmission oil level too low
• Transmission oil quality poor or type incorrect

Coolant inadequate

• Coolant level too low
• Coolant deteriorated
• Cooling system component defective
• Radiator clogged
• Radiator cap defective
• Water pump not rotating

Clutch operation faulty

Clutch slipping

• No clutch lever play
• Clutch cable improperly adjusted
• Clutch cable defective
• The clutch plate is worn or warped
• Clutch spring broken or weak
• Clutch release mechanism defective
• Clutch hub or housing unevenly worn

Clutch not disengaging properly

• Clutch lever play excessively
• Clutch plate warped or too rough
• Clutch spring tension uneven
• Transmission oil deteriorated
• Transmission oil viscosity is too high
• Transmission oil level too high
• Clutch housing froze on the drive shaft
• Clutch release mechanism defective

Gear shifting faulty

The transmission does not go into gear; the shift pedal does not return

• Clutch not disengaging
• Shift fork bent or seized
• Gear stuck on the shaft
• Gear shift positioning lever binding
• Shift return springs are weak or broken
• Shift return spring pin loose
• Shift mechanism arm spring broken
• Shift mechanism arm broken
• Shift drum broken

Transmission jumps out of gear

• Shift fork worn
• Gear groove worn
• Gear dogs and/or dog grooves worn
• Shift drum groove worn
• Gear positioning lever spring weak or broken
• Shift fork pin worn
• The driveshaft, output shaft, and/or gear splines worn

Transmission skips gears

• Gear positioning lever spring weak or broken
• Shift mechanism arm spring broken

Engine noise abnormal

Knocking

• Igniter defective
• Carbon built up in combustion chamber
• Fuel quality poor or type incorrect
• Spark plug type Incorrect
• Engine overheating

Piston slap

• Piston clearance excessive
• Cylinder or piston worn
• Connecting rod bent
• Piston pin or piston pin bores worn

Other noise

• Connecting rod small end clearance excessive
• Connecting rod big end clearance excessive
• Piston ring worn, broken, or stuck
• Piston seized or damaged
• Cylinder head gasket leaking
• Exhaust pipe leaking at the cylinder head
• Crankshaft runout excessive
• Engine mounts loose
• Crankshaft bearing worn
• The primary gear is worn or chipped

Abnormal drive train noise

Clutch noise

• Clutch housing/friction plate clearance excessive
• Clutch housing gear/primary gear backlash excessive
• Metal chip jammed in clutch housing gear teeth

Transmission noise

• Crankcase bearing is worn or damaged
• The transmission gear is worn or chipped
• Metal chip jammed in gear teeth
• Transmission oil level or viscosity too low
• Kick ratchet gear not properly disengaging from kick gear
• Output shaft idle gear worn or chipped

Abnormal drive train noise

Clutch noise

• Clutch housing/friction plate clearance excessive
• Clutch housing gear/primary gear backlash excessive
• Metal chip jammed in clutch housing gear teeth

Transmission noise

• Crankcase bearing is worn or damaged
• Transmission gear is worn or chipped
• Metal chip jammed in gear teeth
• Transmission oil level or viscosity too low
• Kick ratchet gear not properly disengaging from kick gear
• Output shaft idle gear worn or chipped

Drive chain noise

• Drive chain slack improperly adjusted
• Drive chain worn
• Rear and/or engine sprocket(s) worn
• Drive chain insufficiently purified
• Rear wheel misaligned

Frame noise abnormal

Front fork noise

• Oil level or viscosity too low
• Spring weak or broken

Rear shock absorber noise

• Shock absorber damaged

Disc brake noise

• Pad installed incorrectly
• Pad surface glazed
• Brake disc warped
• Brake caliper defective
• Brake master cylinder damaged

Other noise

• Bracket, nut, bolt, etc. improperly mounted or tightened

Exhaust smoke

Brownish

• Air cleaner element clogged
• The main jet is too large or has fallen out
• Starter plunger stuck open
• Carburetor fuel level too high

Poor handling and/or stability

The handlebar is hard to turn

• Throttle cable incorrectly routed
• Wiring incorrectly routed
• Steering stem locknut too tight
• Roller bearing damaged
• Steering bearing race dented or worn
• Steering stem inadequately lubricated
• Steering stem bent
• Tire air pressure too low

The handlebar shakes or vibrates excessively

• Tire worn
• Swingarm sleeve or needle bearing damaged
• Rim warped or out of balance
• Front and/or rear axle runout excessive
• Wheel bearing worn
• Handlebar clamp loose
• Steering head nut loose

Handlebar pulls to one side

• Frame bent
• Wheel misaligned
• Swingarm bent or twisted
• Swingarm pivot shaft runout excessive
• Steering maladjusted
• Steering stem bent
• Front fork leg bent
• Right/left front fork oil level uneven

Shock absorption unsatisfactory (suspension too hard)

• Front fork oil excessive
• Front fork oil viscosity too high
• Front fork leg bent
• Tire air pressure too high
• The rear shock absorber was improperly adjusted

Shock absorption unsatisfactory (suspension too soft)

• Front fork oil level insufficient and/or front fork
• leaking oil
• Front fork oil viscosity too low
• Front fork and/or rear shock absorber spring weak
• Rear shock absorber leaking gas
• The rear shock absorber was improperly adjusted

Poor braking performance

• Air in the brake line
• Brake pad or disc worn
• Brake fluid leaking
• Brake disc warped
• Brake pads contaminated
• Brake fluid deteriorated
• Primary and/or secondary master cylinder cup(s) damaged
• Master cylinder scratched
• Brake maladjusted (lever or pedal play excessively)