2006 KX65 Clutch and Water Pump replacement repair

[@BolognaRingRanch]

This is the most thorough, informative video I've seen. 10 thumbs up!

[@DirtBikeDaryl]

TubeLess Thank you! Glad you enjoyed it.

[@arag1574]

BigRedGrizzly serious thank you, I'm in the process of rebuilding my 65 and converting it to a motard and my water pump is shot

[@DirtBikeDaryl]

Ara G Glad it helped you out. Have fun!

[@dickiecoates6833]

And thanks for ensuring the camera was steady that really makes a big difference

[@sinikl]

I just used this, in conjunction with the factory manual, to do the clutch in my son's Christmas present 04 KX65. Very helpful! Thank you so much for this video. In my case, the previous owner(s?) had gone crazy on the clutch hub nut and it took jamming the motor with a bar thru the sprocket across the swingarm, 5th gear and the brake on, and a 2 foot cheater to get the clutch nut loose (!). I ordered a piston stop but it's lost in the mail 15 days later (2020 vibes). Don't give up hope; it really is a lefty loose-y thread and if your impact tool won't work, you may have to resort to some extreme Measures. Also pro tip: when BigRedGrizzly refers to the sharp and rounded side of the plain plates... do not check them by running your finger over them unless you enjoy paper cuts administered by finely machined steel. Especially in this time of COVID and hand sanitizer! Great video, thanks much.

[@DirtBikeDaryl]

Thanks. Glad the video provided a nice visual aid a supplement to your manual. Good job getting it done ✅.

[@mircograssilli1014]

Hi there, I'm from Italy, I have the same motorbike for my son. Today we went to the box to take the bike and ...aaarghhh... there was a small oil pool under the engine!!! I bought the bike as second hand and realized the previous owner had the clutch disks changed, but did not change the main gasket, so I think I'll have to change it myself. THANKS FOR THIS VIDEO, which fully explains, step by step, how to do the work!

[@DirtBikeDaryl]

Mirco Grassilli Hi Mirco.... Glad the video helped you out! 👊🏻✊🏻💨🏁

[@armandosantana4544]

Awesome video, thank you for taking your time to share this with us.

[@alvinleandro5794]

Instablaster.

[@michelregimbald9080]

Thanks for the video, you are a great teacher

[@DirtBikeDaryl]

Thank you. Hope it helped you.

[@namensedar]

Great video. Nice calm and methodical!!!

[@stephanharlow288]

Thanks so much for the amazing detailed video it has really been helpful

[@DirtBikeDaryl]

I’m glad it helped you out. Happy Thanksgiving 🦃

[@dickiecoates6833]

Awesome video pal, well done, very helpful thank you dude.

[@DirtBikeDaryl]

Dickie Coates Thanks. Glad it helped. 😊

[@johngravo7776]

For anyone that needs to lock up a cylinder... grab some 1/4" nylone rope. Pull the spark plug and pack it above the piston. It'll hold everything nice and tight to get stubbon bolts undone. Cheapest engine lock up tool ever.

[@DirtBikeDaryl]

Yep… Good tip. I do that when working on chainsaws. 👍🏻

[@johnnyturbo8460]

Well done... subscribed

[@jspecricer2734]

Very helpful video, thank you

[@DirtBikeDaryl]

I’m glad it helped you. 👊🏻✊🏻💨

[@dianachristoffersen8900]

Hi I really appreciated your video I have replaced a clutch kit on a kx 60 today and getting ready to put everything back I had a question... I’m putting in new gasket... do I just put the gasket in dry? Or do I need to lube it w something? Thanks for your advice

[@DirtBikeDaryl]

It’s ok to put it on dry. I have put little bits grease to help hold it on before. Ideally, you would want the alignment dowels in the engine case and not in the cover. The alignment dowels will help hold the gasket as well. The alignment dowels are those thin walled cylindrical tubes.

[@joshalmeida1821]

I was able to successfully replace the clutch on my son's KX65 thanks to your video! Thank you so much. Quick question though, could you link me to the piston stop you used? I've seen some that are metal but you said yours was plastic which I think would be better

[@DirtBikeDaryl]

Josh Almeida I’m so glad it helped you out. Doing it once will now basically give you the ability to do it on any dirt bike. Great job. Here’s the link to the piston stop. www.rockymountainatvmc.com/parts/steahly-engine-lock-up-tool-p

[@rydawg8694]

Hello I need some help my bike is a kx 60 and I can't get the Bering out what way do I push the Bering out

[@marcelborkent7894]

Hi, i used this clip today to do my first ever work on my sons kawa 65. I am not a trained technicall guy but was able to pull this of. Great thanks for the movie. This week i will also do the piston, any good movies on that?

[@DirtBikeDaryl]

Marcel Borkent Actually, yes. I just did my son’s. kzbin.info/www/bejne/anOnoXpmjNiqqcU

[@jaycup4335]

Hi there having a little trouble getting that bolt torque to 47 pounds my tire wants to spin I strapped the bike down and try to put it in different gears but the tire won’t seem to lock it keeps spinning when I try to torque the bolts any help would be great if I’m doing something wrong thanks and thank you for making this video helps a lot just trying to get this boy’s bike fixed!

[@DirtBikeDaryl]

jaycup 433 I understand your difficulty in getting that clutch bolt to 47 ft. Lbs. what you don’t see is that I have a piston stop installed where the spark plug goes. When the piston moves up the cylinder and hits the stops, it basically locks up the engine so you can tighten that nut. Another option would be a clutch basket holder. That will allow you to hold it still as well. Piston stops are cheap. www.rockymountainatvmc.com/parts/tusk-engine-lock-up-tool-p www.rockymountainatvmc.com/parts/tusk-clutch-holding-tool-p

[@jaycup4335]

Thanks I’m learning, it all makes sense now 👍

[@DirtBikeDaryl]

jaycup 433 We all start somewhere. I love learning mechanics and I’m happy to share what I know. 👍🏻

[@baronkostek1]

dziekuje !

[@cnc.moto_factory]

If I'm replacing just the clutch plates, do I need to remove that circlip from the crank gear still?, or can I leave the circlip and gear on and just remove the clutch basket? The plastic teeth on the water pump gear looks good on my bike, so no need to remove or replace it. Thanks! Great video and info.

[@DirtBikeDaryl]

cartercochran mx Hi Carter... You DON’T need to remove the circlip or that primary drive gear. Actually, if your only replacing fiber plates all you have to do is remove the springs and the pressure plate. Then reassemble. Be careful tightening down those pressure plate screws with the springs. Use a torque wrench if possible... 👍🏻

[@cnc.moto_factory]

@@DirtBikeDaryl Also, I dont have a piston stop. So can I just remove the exhaust pipe and shove a metal bar up the cylinder port to stop the piston from moving? Or how would you reccomend I take the clutch basket off if I dont have a Piston stop? Thanks!

[@DirtBikeDaryl]

cartercochran mx Now I know you’re just F’n with me! Lol... Have fun Carter... 👊🏻✊🏻💨🏁

[@Temp354]

To replace the crankshaft only… do I need to take all the gears and transmission out?

[@DirtBikeDaryl]

No, I don’t think so. They are only connected by the clutch. So if you are able to separate the clutch and and spilt the cases you should be able to press the crankshaft out no problem. If you’re in there that deep though, you may want to consider replacing other worn parts if they are worn. Good luck, take lots of pics, it helps with re-assembly.

[@Temp354]

@@DirtBikeDaryl I also noticed when I was taking apart my bottom end on my KX 65 I noticed the gear that’s attached to the crank and holding the clutch. Mine had a bold on the end of it. I didn’t see yours having a bolt on the end so I’m not sure why mine has one.

[@scrapbaby6863]

So what other gaskets are required for this job besides the water pump and case gaskets?

[@mikejaniak1436]

Do you happen to have all the part numbers ?

[@Mikehoncho191]

I did all of this but the clutch still sticks even when I adjust it all the way out, what causes this?

[@charbeljosefsson9163]

Nice video!! The small oil seal in the water pump, Will the flat side facing me?

[@DirtBikeDaryl]

www.manualslib.com/manual/803743/Kawasaki-Kx65.html?page=60#manual Definitely look at this link. It all depends on what perspective you are referring to. The link will clear it up.

[@deveryadams3930]

I need a 2007 kx65 harness cdi stop switch and stator system to buy do you have any i can't get any on Ebay or Amazon can you help me please try and locate me with someone who may have or can another it be replaced with another year kx65 model.how what size are they can they replace with other years kx65 model or can i used one for a another model ?

[@davidcurtis747]

Hi thanks tor this video it's been helpful but I'm on the last bit the small oil seal that is on the outside neares to the impeller I put that on and it feels pretty loose do I need to try and drive it in further the seal has the writing on facing out towards the impellor

[@davidcurtis747]

It's the smaller seal or is supposed to be with the writing facing in to the other seal as I couldn't see on your video which way it sat thanks in advance

[@DirtBikeDaryl]

You have that outer seal facing the correct direction. It should be flush with the casing. If it is loose it may be incorrect size. One can push it in with their fingers but it should be hard to do.

[@davidcurtis747]

@@DirtBikeDaryl thanks mate I'll try n put a socket on it in the morning n try and drive it in just a little further but thanks for the vid I'll subscribe to. Your channel 👍

[@davidcurtis747]

Or I'll put a clamp on it and get it just a little further in

[@dianachristoffersen8900]

Daryl can I take a picture of a spring and you tell me where it goes I’ve got everything back but I’m not sure where this goes

[@DirtBikeDaryl]

Sure. You can got to my dirtriderlab Facebook page and submit it to me there.

[@dianachristoffersen8900]

OK I sent it to Your messenger

[@bradymxr4659]

Did the water pump make a noise when running?

[@DirtBikeDaryl]

Nothing abnormal.

[@bradymxr4659]

@@DirtBikeDaryl my son’s 2009 sounds a little noisy by that area. That’s why I asked. Might be taking his apart and put new parts in and see what’s going on.

[@DirtBikeDaryl]

@@bradymxr4659 The bearing in there my be a bit f’d. It would likely be best to get in there and see what’s going on. See if there is water/antifreeze in your oil. Milky looking oil will be the sign.

[@bradymxr4659]

@@DirtBikeDaryl that’s what I did right away but still good. So I’m tearing into it.

[@DirtBikeDaryl]

@@bradymxr4659 Nice. Let me know. I’m interested to hear what you find. Good luck. 👍🏻

[@robertmarcum4359]

I need help with my kx65 when I try to untighten the center clutch backer bolt my clutch just strips even if I put something to wedge the gear

[@DirtBikeDaryl]

Robert Marcum Sounds like you need to lock it up. You will need a piston stop, flywheel holder, or clutch basket holder. www.rockymountainatvmc.com/parts/tusk-pin-style-flywheel-holder-tool-p www.rockymountainatvmc.com/parts/tusk-clutch-holding-tool-p www.rockymountainatvmc.com/parts/tusk-engine-lock-up-tool-p

[@JohnSmith-ir5pv]

Any videos on fork rebuilds for this mamer jammer?

[@leadhead7338]

If you don’t have any special holders to stop it, you can literally use a flat head screw driver, it’s not the best option but that’s what I’ve done in my driveway rebuilds

[@badger1335]

Do you think on a kx85, basically the same clutch, that if my water pump seal has gone bad (which it has) and it starts to leak water into the clutch, could it cause it to slip and screech? I also have a nylon gear that I'm buying a replacement for because it has a couple teeth missing in the water pump assembly, could that cause screeching too?

[@DirtBikeDaryl]

I suppose it could. If your clutch is slipping it could be that your clutch plates are beat and need replaced, the clutch springs are out of spec. and need replaced, or spring bolts are out of torque spec and need retightened. Definitely do not over right those clutch spring bolts. They snap easily and you’ll have a bigger problem on your hands. A service manual with torque values is likely available on line.

[@piercecid7156]

Don't you have to soak the clutch plates?

[@DirtBikeDaryl]

Yes… In this video you can see that I’m pulling them out of a plastic bag containing the oil and the fiber plates. If done as little as 3 hours and as much as 24. Never noticed a big difference. I would always get them nice and oily though before I installed them.

[@chadlarsen8084]

How do you pull out the water pump shaft?

[@DirtBikeDaryl]

chad larsen If I remember correctly, I think it just pulls out from the inside of the cover.

[@chadlarsen8084]

Do I have to take off that bolt for the impeller to pull it out?

[@DirtBikeDaryl]

chad larsen I’m pretty sure you have to remove the impeller.

[@DirtBikeDaryl]

chad larsen Yes. I’m pretty sure that what holds the shaft to the cover.

[@chadlarsen8084]

Sorry for all the questions but I can’t take the bolt off it keeps spinning

[@michaeldoran5001]

Thanks a lot pal but I can't get anything from there because I live in the UK and they don't sent stuff out to here do you know the name of the part though?

[@DirtBikeDaryl]

Michael Doran Yes... Water pump shaft. FYI... You can still look up the part to find out what it’s called. I hope you get your bike back in action quickly..

[@michaeldoran5001]

I have put that in and it's not bringing that piece up just the metal bit

[@DirtBikeDaryl]

Michael Doran For us here in the states it’s one part. The plastic gear comes already attached to the metal shaft. I would think it would be the same over there...

[@bobthenob9017]

@@michaeldoran5001 did you sort it ? I am also from the UK and found that part easy, type in on Google kawasaki oem part UK and you will be good or go on ebay couple on there at the minute :)

[@Xxcody3232xX]

Just rebuilt a 05 rm65 clutch isn't working. Also the shifter lever wont return to center. Just sticks. Any ideas ? Anyone...

[@michaeldoran5001]

Hi what is that part called that you took out of the water pump with the plastic teeth could you let me know asap please

[@DirtBikeDaryl]

Michael Doran I’m going to teach you how to look it up. Go to Rockymountainatvmc.com and look at the parts fiche for your bike. Go to the OEM section and enter the info about your bike. It’s under the engine cover tab. You can look up all parts by doing this and it doesn’t cost you but a couple minutes time. You give a man a fish and he can eat for a day. TEACH and man to fish and he can eat for life...

[@lek2455]

What kind of antifreeze do you run?

[@DirtBikeDaryl]

Peak 50/50

[@moneyman4202]

What oil do you mix with gas?

[@DirtBikeDaryl]

Moneyman1221 Klotz Techniplate 👍🏻

[@thegametown1584]

Yamalube for the win

[@cockshoemagoo2]

Tcw3....... marine grade 2 stroke oil. 32:1

[@masonparker978]

My clutch cover won’t budhe

[@DirtBikeDaryl]

Make sure your alignment pins are in and set all the way in. Sometimes they bind things up and make it difficult to get on.