Kawasaki KX65 Complete Bottom End Rebuild | Wrench Rabbit Kit
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- Опубліковано 25 лип 2024
- A long time coming, I edited down about 3 hours of footage into this lovely video detailing the KX65 bottom end rebuild.
For the bearing that was not included in the kit here is the part number and a link to partzilla:
Part # 92045-1304
www.partzilla.com/product/kaw...
Affiliate Links:
Wrench Rabbit Kit: amzn.to/3yshE4p
Tusk Crankcase Splitter: amzn.to/3fylGRR
Tusk Clutch Holding Tool: amzn.to/3xrUnOT
Tusk Crank Puller/Installer Tool: amzn.to/3lydYus
Tusk Crank Puller C - Clip Adapter: amzn.to/37qvuIG
Motion Pro 08-0026 Flywheel Puller: amzn.to/3rV1UEN
Oil Fill Cap: amzn.to/3CmMBJB
BR10EG Spark Plugs: amzn.to/3ysrV0J
Motul 710 2T Full Synthetic Premix: amzn.to/37D79jf
Motul 7100 10w40 Synthetic Engine Oil: amzn.to/2TWHcrs
Moly Grease: amzn.to/3lBdX8V
Oil Squeeze Bottles: amzn.to/3fChyjo
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Music
Outro:
Retnik Beats | www.youtube/c/retnikbeatsbe/
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0:00-2:10 - Wrench Rabbit Unbox
2:10-11:52 - Bearing and Seal Install
11:52-16:21 - Crank Install
16:21-20:34 - Transmission Install
20:34-28:12 - Sealing the crank case
28:12-29:48 - Stator and flywheel install
29:48-43:26 - Kickstarter, Clutch, and Shifting Mechanism Install
43:26-46:04 - Water pump
47:03-47:43 - Stator Cover - Авто та транспорт
Now that I no longer have the KX65 along comes this most useful how to video. Thanks for providing this most excellent How To Video.
Glad it's helpful haha, now you just need another KX65!
@@GarageAddiction Yeup!
Thanks for your reply
I took the kick starter plastic ring off and I didn't have the spring in the notch.
I could of never done this rebuild without you doing this video thank you very much
Glad it helped out with the rebuild and happy you found the issue!
What a great video. Thank you so much for saving my engine!
Extraordinary video.
Nice! Thanks for the vid.
Just got my son a WR kit for his 03 Rm 65, ty for your video .
Awesome, hope he has some fun with the rebuild!
Thank you for this video
Nice nice, I was waiting on this
Hope it's helpful!
This will totally be helpful thanks alot
I’m doing my sons soon but when done it will look like a new off the shelf engine. Just some vapour blasting and new bolts makes the job satisfying rather than rushing and the engine looking as it was. Good job though for an rookie 👍🏻
Haha if I had the space for a vapor blaster and an oven for cerakote I'd go ham.
I gain more knowledge, this is a great content, nice tools
Thanks!
great video
Thanks!
Yeah man merci
Thanks
Rebuild mines today you probably got like 40 more views just from me alone lol
Hope it helped :)
just curious of any updates on your thoughts of how the hot rods kit is holding up for you? any issues come up yet? thanks i just picked up the wiseco top and bottom end kit but realized it doesnt come with any of the transmission bearings etc.
No issues at all so far, I think I've got about 30 hours on it. (I really need an hour meter)
Nice video , got here becuase im looking more info on that brand that does thatkit im looking into the kx100 03 bottom end kit , it seams they made a nicr kit for 65 hopefully the 100 one is good too
I've really liked the kits. Haven't had any issues with them yet.
After installing my clutch cover, the shaft/lever that engages the pilot bearing which pushes on the pressure plate is rock solid. There is only free play but nothing else. Not sure whats happening with the clutch assembly but something does not feel right
It takes a good amount of force to move the lever and actuate the clutch but if it's binding it may be that the inner clutch hub is not fully seated in the outer basket, loose bolts compressing the clutch springs, or possibly the shift arm was out of alignment when the cover was installed (seems unlikely on the last one)
I would imagine this is extremely similar to a 2000 KX 60. I’ve been rebuilding my childhood dirtbike and a lot of it is almost exactly the same. From I can see so far
Awesome that you’re rebuilding your childhood bike! The kx60 is pretty similar for sure.
I finished the motor and finally started up the old kx60! Thanks to the manual and your video I was able to rebuild the motor.
The kx65 and kx 60 are very familiar. The water pump is a little different and the crank connection to the crank puller is a bit different, other than that it’s almost identical
@@MrJeffharper47 good to know honestly. need to do a right side case swap/crank swap so gonna go ahead and swap bearings and seals.
Parce I'm From Colombia...
Mi respeto para usted, hasta el momento lo que he Visto, sabe armar estos motores, se ve que se trabaja muy organizado y con bastantes herramientas específicas...
Acá se arma como se pueda, para darle guaya y salir a correrla como se debe....
Saludos desde Colombia...La Buena..
Parce, con todo respeto.
Sería bueno que limpiará bien los orificios dónde lleva los retenedores, se ve mugre y eso es importante a la hora de armar, de resto muy buen programa
I had to run this through google translate but thank you! I would love to get a parts washer and some other tools to help clean the parts more meticulously, hopefully in the future! Cheers!
👑KX👑
what is the moly for
Awesome video! Do you happen to remember what bearing the wrench rabbit does not come with for the water pump? I’m actually in the process or rebuilding one now and don’t have that same bearing.
Thanks! I do have the part number, I threw it in the video description!
Just finished putting together my ktm 65 sx. Once I put the cases together I can’t spin the shaft for the bottom end, I think it’s in gear I don’t wanna put everything together just to take it apart. Does this matter if it doesn’t move to much?
I'm not super familiar with the KTM platform but you should be able to spin everything in the transmission by hand even when in gear.
To run through all the gears ⚙️ at 33:58. Do I have to have the crank installed to check that? And do the cases have to be together?
You can spin the shift drum once all the gears are in place. Just make sure you put a little pressure down on the drum while you turn and make sure all the shift forks move freely.
The shift drum turns twice. All forks are in place. I’m gonna put the cases back together once the Crank puller comes in
Did u buy the sir clip for when u pull the crank
I had to buy the circlip collar for the tool and I used the old circlip to pull it through.
What year did they switch the primary gear to a reverse threaded nut? My 2018 has a nut on it instead of the snap ring.
Looks like 2006 they moved to the nut over the clip
What is the stand you use to Assemble the engine on? Also you happen to know what bearing is needed for a kx60 water pump if figured there the same. Also where did you get the bearing tool from?
This is the engine stand I use: amzn.to/3wGoDXO
I modified it slightly by putting felt on the edges of the tray and a bolt through one leg to keep it from squeaking while working on an engine.
The bearing tools are from Harbor Freight but you can find them on amazon too: amzn.to/3lJbWXr
For the bearing on the kx60 this would be the corresponding bearing depending on the year: www.partzilla.com/product/kawasaki/92045-1305?ref=f717db9cb907d81ac151416246fe90285c741216
He literally said he got the bearing tool from harbor freight brah.
So was the inner water pump shaft bearing the one not in my kit is this kx 60 one going to work my engine says 65ae ? 🤔
Are all the case bolt towards the sprocket the same I broke one off and I can't find a part number it's the one right to the left of the sprocket numb
The case bolts are slightly different in length, I think the spec bolt kits have similar lengths though. www.partzilla.com/catalog/kawasaki/motorcycle/2005/kx65-kx65-a6/crankcase
Does it matter what side the dowel pin on the shift drum is positioned if it’s on the right or left??
I don't believe it matters
Can you link me where you got the Bearing and seal driver
This is close to the same set: amzn.to/3xvaqLZ This is the one I actually picked up: www.harborfreight.com/bearing-race-and-seal-driver-set-10-pc-63261.html
Do you have to apply Yama bond on the case?
The shop manual calls for Kawasaki liquid gasket but I had yamabond on hand.
where do this big o rings go from the kit? i have no idea lol
The large orange ones? Those are for the expansion chamber where it seats into the cylinder.
Can you hammer the bearings in if you don't have e a press?
Heat up the cases and they will come out easier. Most can be hammered out, there is one that needs a blind bearing puller or some bread. ua-cam.com/video/y2ggE0rC3g0/v-deo.html
Your videos are amazing! You don’t have any interest in rebuilding my daughters 05 kx65 do you? I believe it’s the exact same situation.
What year model is this KX 65? Because when I tried to pull my crank in mine looks different and I’m not sure how to pull it through. I have the 2006
Mine is a 2005, should be threaded on the stator side and use a circlip on the clutch side
But great vid by the way.
Thanks!
i did a complete fresh rebuild on an rm65. fired it up runs great lots of power but my issue is 5th and 6th gear aren’t there. 4th runs fine and strong once i shift up into 5th it’s like neutral just revs. won’t shift up any higher acts like it’s topped out no more shifts left. any idea what could be wrong here? maybe i installed something wrong or missed a worn part??
I'd pull the clutch cover off and see if you can shift through the gears watching the shift arm and drum. Unless those are installed incorrectly or broken it's probably something on the transmission side like a worn or broken shift fork.
Got one right now I’m working on, have done everything you’ve done but won’t shift passed 1st gear? Any ideas
Check the shift star and shift arm, might be an easy fix if the arm is off. If not I would split the cases and check the shift forks. Also when shifting through the gears make sure to spin the countershaft.
Do I need a press for the bearings and seals?
A press makes it a lot easier but heating up the cases and freezing the bearings does a great job as well. I would suggest the bearing driver kit and a rubber mallet.
What’s the mounting system you have to hold the engine?
This is the engine stand I use: www.denniskirk.com/motorsport-products/black-gray-engine-stand-60-1002.p1401322.prd/1401322.sku?cid=17923638713&gclid=CjwKCAiA3KefBhByEiwAi2LDHGpcR1iVBvecq8VpHjV6rxL5Muup1o_JjNzpRlqOGB60lcr7NA16KxoCzkIQAvD_BwE
I modified it slightly by putting felt on the edges of the tray and a bolt through one leg to keep it from squeaking while working on an engine.
I recently rebuilt my kx65, it ran great for about an hour then locked up I noticed that the crank had slid over in the cases which caused it to lock up when pushed against the side of the case has all brand new bearing and seals I cannot figure out what I’ve done wrong could you possibly tell me what I’ve done wrong if you know.
Did you replace or reuse the crank?
Another question, I ordered the crank puller kit, and my c clip does not fit on my crank and the adapter doesn’t slide over the gear on the crank, could you possibly provide me the link of the adapter you used
I used this adapter and a c-clip from a generic harbor freight kit since it will generally bend the clip when getting tight.
amzn.to/37qvuIG
Just bought my buddy's old 2005 kx65 for 80 bucks he just did the top end so this gone bw my first 2 stroke build should be fun bikes are n great shape other then it's locked up but wasn't any metal shavings in the oil so hope it's not the trany or something
If there was no metal it may be the crank/bearings. Hopefully it's something nice and easy on the clutch side though
bro I’ve got a kx65 and it was running perfect until it just slowed down on its own and felt really hard to kick over? it might be the piston or something bro what would your advice be?
Sounds a lot like bad crank bearings. You can pull the pipe and take a look to see if there is any visible carnage, if it looks fine pull the head off. If there is nothing on the cylinder/piston it's probably bottom end.
@@GarageAddiction thanks a lot brother 🙌🏼
Where did you find the bearing for the inner water pump that goes on case side
Got it in the description! Cheers!
Part # 92045-1304
www.partzilla.com/product/kaw...
Page is gone any other links to the missing bearing the kit should have come with ?
Where can I get the bottom part kit for my 1988 Kawasaki kx80
Not sure on that one, checked a few places but didn't see any. Might have to assemble one from a parts fiche.
My kick starter doesn’t retract back, what could I have missed when reinstalling?
there are two springs on the kickstart mechanism. It's possible the inner spring has come out of its housing and the plastic cap shifted or maybe the main spring wasn't wound before the cover was installed?
I rebuild my engine but its very hard to shift up and down that you have to use your hand
Try pulling the right side cover and make sure the shift star and arm actuate properly, may be getting hung up if something is loose or misaligned
Stupid question but was that the blue or red loctite you were using?
Blue, I'm not a fan of red. Red is such a pain in the butt to remove and I haven't had any issues with the blue.
Like, does it matter if the dowel pin on the shift drum is on the right side or the left side
Did you ever find out? I was thinking the same
It would be understandably more difficult without the press, but is it possible to just freeze the bearing and use the bearing drive set to hammer them in, I just got the parts for my rebuild and wanna make sure I’m doing it right
Definitely doable with a freezer/driver. You can heat the cases up as well to make it easier just be careful once you get the right side seal in in not to roast it. An arbor press would probably reach all the bearings as well and they're pretty inexpensive.
@@GarageAddiction thanks for the help, once I get the tools I’ll be ready to tackle it, let’s just hope I don’t strip very many bolts 😂
Link to that bearing press?
Harbor freight specials!
www.harborfreight.com/12-ton-shop-press-33497.html
www.harborfreight.com/bearing-race-and-seal-driver-set-10-pc-63261.html
After doing this every seems to work except when I kick the kick starter down it stays down until I pull it up by hand.
It works correctly as long as the case is loose on that side.
Any ideas to help me out would be greatly appreciated.
Interesting that it works with the side case loose. Check the alignment on the shaft as well as the water pump to see if anything is binding up
A Bearing not in all the way?
That nice rack you got there is awesome, wish I had one of those.
What was the red stuff I no it was lubercation but any specific name or what not and also bro ur amazing u seem to no ur stuff dude I could never do that stuff lol
The red stuff is engine oil, Motul 7100. Thanks man, give it a go it gets easier as you keep working on stuff!
What year bike did you do this on
2005, KX65s are very close from 2002-present. They do change cranks but that's just moving from cclip to nut on the clutch side.
I've been having lots of issues shifting through my bike. I have torn the bike down, and now i am redoing the transmission. I've been following step-by-step on the lowest speed on the video when you're installing the transmission, and when i do it, my bike wont shift. it's just stuck. I've been trying to figure it out for a few weeks now and i have found no solution. Help please.
Diagnosing any issue through youtube comments is borderline impossible. Jump in the discord I just linked in the description and we might be able to help you out.
Hello is there a 5 speed gearbox for kx 65cc?
I've definitely never seen one.
@@GarageAddiction ok thanks, Nice vídeo congratulations 👏
I've been around to other videos as to not harass you to much, lol. But none that I can find are as good as yours and let alone that it's the same exact setup. I have compression in the kick start, I have a strong spark, clean new fuel premixed for 2stroke. Clean air. I can't even get a single fire (explosion) out of the piston using starter fluid with the carb off. If I can't get something as simple as that what the heck could be wrong?
I have checked the timing on the stator to the plate /holder behind it. It's all lined up. I tweaked it both ways, nothing. I used different spark plugs, nothing... I clearly do not have experience with this but for goodness sake it shouldn't be this hard! I'm goin on 2 days now and can't even get a fire /pop /single explosion - let alone getting it to start.
I bet your pilot jet in your carb is clogged. Happens a ton on these bikes if they sit at all. Pull the bowl off and check that real quick.
@@GarageAddiction I’ve been through it several times. Since I can’t get a single fire I’m thinking the timing is off. But I’ve set it back to where it was prior And when lined up at those settings the piston just so happens to be just barely under fully to the top; as I’ve seen in several videos.
How would you know when to do a complete bottom end rebuild. I’m a new noob trying to lean how to take care of these 2 stroke bikes. My daughter is on a kx65 that I got used. 2017 it still pulls but I know they say you should redo the top after so many hours. She’s not a hard rider right now as she’s still learning also but if I can keep up the maintenance I’m hoping the bike with last a lot longer. Even though she’s 11 I’ve been told she should be on a 85 if she’s trying to get into racing. I guess different circuits have different age requirements for the size of bike.
There are some general hour intervals but they tend to be too short in my experience. My top ends last about 30 hours for rings and 60 for pistons, my last bottom end survived over 200 hours. If you notice a lack of power it's a good time to check the top end, while you're in there make sure there isn't any vertical play in the rod. Depending on the racing org and her height weight etc the 85 may be a good option.
Ya she’s 70lbs at maybe a lil over 4ft. She’s 11.
The person before said he raced the 65 as a pit bike he was a late 20’s guy. The only thing was it came with a sand tire. That’s what raised my suspicion it was ridden kinda hard. But its still pulling strong. I just don’t want to be one of those guys you waited to long and now it caused more damage then I should’ve done this earlier.
I wouldn’t worry about it too much as long as you’re running a good oil ratio and doing frequent oil changes. If you’re really worried you can rebuild the whole engine and track hours but id run it and do a top end after 20-30 hours. You can check the crank play while you’re in there and if the crank bearings go you’ll get the opportunity to refresh the whole engine
She must fly on the 65!
used this video to rebuild my engine it runs! but the clutch doesnt work. the clut ch actuator shaft has play left and right about an inch or so too and wont engage clutch
If the shaft has that much play it's probably not engaging with the pin that sits in the bearing. Take the clutch cover off and see if the pin slipped or perhaps the clutch arm was not lined up when the cover went on.
@@GarageAddiction i lined it up, taped it at the hole like you did and the manual says. ima take it off though thanks bud
Would you rebuild another one if I sent it to you?
It would be waaaaay cheaper to take it to a local shop than to send it my way :)
Hello I would like to know if this kit works on a 2008
amzn.to/3EqhijB This one would work for the 2008
@@GarageAddiction thank you for the information sorry for the late response.
Theres clear epoxy or something on my waterpump gear is that normal lol
That doesn't sound normal at all. Cheap insurance to replace that sucker before it comes apart.
When I put the cases together mine literally dropped right in. Good video tho
Thanks! Anytime I put in a new crank it takes a good squeezing to get my cases back together
what is the part number or do you have a link for that missing bearing that you had to order at 7:28 ?
Ah good call, I forgot to add that in the description: 92045-1304 www.partzilla.com/product/kawasaki/92045-1304?ref=1b641289c722248ba7b10d2b6b28be4fb41989f2
@@GarageAddiction Thanks!!! Awesome Video..been ordering all the parts and am about to have my mechanic friend do exactly what you have done on this bike, take it apart, figure out what was the issue and put it all back together with the same rebuild kit and most of all the parts and tools you have linked in the descriptions! Thanks so much! do you have a link for the water pump impeller as well?
@@EcoPuraH2o Thanks! Glad it's helpful! Here is a link to the impeller I picked up as well www.partzilla.com/search?q=59256-1064&ui=typeahead
Great video but, I've never seen hot rods cranks last very long.its a great kit but just don't trust them enough. Stock rebuilt is the way to go...
Stock is great but I've had this Hot Rods crank in here for over 50 hours with no issue so far, once it goes I'll update on my thoughts
what year is your kawasaki?
2005
@@GarageAddiction do that kit fit in my 2003 kx 65
@@Jaskajokunen.. I imagine it would but this is specific to your year amzn.to/3IdYpCz
@@GarageAddiction thank you😃
I am from finland and i love your videos
@@GarageAddiction your videos help me very much on my kx 65 project
You sound like Cameron
Niemela?
@@GarageAddiction yep
@@GarageAddiction like exactly alike is this his second channel?
@@405dalton haha, I wish my builds were that clean
Put my transmission in just like u and it won't spin all the way around
Check the gear alignment and the shifter forks. Those like to pop out of the tracks pretty easily when assembling.
There's no washers anywhere on them gears right just making sure I didn't loose anything
@@zacharycoy4704 www.partzilla.com/catalog/kawasaki/motorcycle/2005/kx65-kx65-a6/transmission