Maintenance & Technical > KX100 / KX85 / KX80 / KX65 / KX60
KX60 HELP! In need of rebuild!
Friar-Tuck:
Here is the retaining clip and how to install it.
This should resolve your sticking throttle.
Let me know if you need some pic's on installing the throttle cable to the slide valve.
This little clip is slick, small and hard to see when you drop it... While I was taking these pic's it shot across the garage and i would have never thought I was gonna find it. Small miracles happen every day!
This is the slot in the end of your throttle cable, the clip (When inserted through the slot in the brass adjuster)
Locks the throttle cable sheath to the top of the carb.
And the slot the clip slides in to keep the whole mess together.
Insert the end of the cable into the adjuster, line up the slot in the end of the throttle cable.
Insert the Clip insuring the flat side of the "D" fits into the slot in the end of the throttle cable.
chris-mets:
Hey Tuck,
I have installed the throttle cable to the slide before but am new to this clip installation. Should only take me 5 mins to get on how to do it though lol. Did you receive all the parts yet? If so, is the engine shipped out? Thanks.
Chris
Friar-Tuck:
CM,
I'm expecting the parts today or tomorrow, I'll let you know when I get them. You could be riding monday or tuesday.
You will more than likely have to remove the carb to get the engine in, so I'll put it in a separate box. I'll send it off with your book You can hook up the carb and put a zip-loc bag around it and wait for the rest of the engine.
I'll send it off today.
Here is the Slide and needle assembly, I want to make sure you got it.
The slide and needle
Put the spring over the throttle cable
Hold the spring back and put the cable in the slide and move it over to the "small" side of the keyhole in the slide.
Drop in the retainer and see that it sits flat with the tab in the eye of the keyhole.
Release the spring and see that the spring holds the needle/ cable holder flat in the bottom of the slide.
Drop the slide in the carb slowly minding the needle needs to drop in the needle jet and the large notch in the slide lines up with the idle screw. There is a small notch on the backside of the slide that keeps everything lined up as the slide moves up and down in the carb body.
chris-mets:
Ok, now I fully understand. Thank you for taking all the pictures to guide me through. I will be looking for the carb and manual. Where did you end up putting the mystery washer? Ok, lets go through the whole process when I receiv everything back. Ok so take the engine, connect the chain and bolt it in. Connect the carb properly. Connect the spark plug cord and the clutch cable. Connect rear brake. Connect all the hoses and other stuff. Fill with oil. Fill with antifreeze. fill with gas. Put all fenders and seat on. Ready to go?
Chris
Friar-Tuck:
That sounds about right, Bolt the Engine in and fill the Tranny connect your rads and fill. -> Ignition Wires
Carb, There is a little notch in the top of the carb boot, line up the notch on the carb and tighten the clamp(s) Make sure the throttle operates the slide properly The little brass fitting on top of the carb will also adjust your throttle freeplay. Check your clymer in the fuel section.
Spark Plug & Wire -> Chain & Brakes If the kill button malfunctions and you have to kill the engine put it in gear grab both brakes and let out the clutch...
Fuel tank and seat -> Fenders Then start your break-in. I put a sticky note in the section of the book.
It should be pretty straight forward. I'll get the parts on and ship her out as fast as I can. I would like to see a vid of you whooping it up as bad as you would like to make one!!
Oh yea... The washers went on either side of the clutch basket. See Fig.# 92022
http://www.motosport.com/dirtbike/oem-parts/KAWASAKI/2000/KX60/CLUTCH
Tuck\o/
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