This manual covers the KX85 and KX100 models produced between 2001 and 2010. These liquid-cooled, two-stroke dirt bikes are designed for motocross and off-road competition, known for their strong mid-range and top-end power delivery, and are a crucial step in performance-oriented mini-motocross lineups. With a history of racing success, the KX series is celebrated for its handling, adjustability, and competitive performance, making these models highly regarded by aspiring racers.
This comprehensive English-language service repair manual provides detailed, step-by-step instructions for maintaining, troubleshooting, and repairing your KX85 or KX100. It covers all major systems, including the engine's top-end, right-side components, bottom-end and transmission, fuel system, cooling system, wheels, tires, final drive, brakes, suspension, steering, frame, and electrical system. This manual is an indispensable resource for owners and mechanics, offering guidance for routine maintenance, adjustments, component repair, and full rebuilds, ensuring your motorcycle performs at its best.
Model Code Kx85:
KX85-A, KX85-B
Model Code Kx100:
KX100-D
Specific Model Codes Covered:
KX85-A1 to KX85-AAF, KX85-B1 to KX85-B9F, KX100-D1 to KX100-D9F, KX85D8F, KX85AAF, KX85AF
Target Audience:
Owners, hobbyists, and professional mechanics seeking to maintain, repair, or restore Kawasaki KX85 and KX100 dirt bikes from the 2001-2010 model years.
Manual Advantage:
Provides an exact digital replica of the original factory service manual, offering clear, detailed, step-by-step instructions crucial for accurate repairs and maintenance, with the added benefit of digital zoom functionality.
Ease Of Use:
Designed for ease of use, with clear numbering corresponding to parts and procedures, making it simple for users to navigate and follow repair steps, thereby saving time and expense.
Benefit:
Empowers owners to perform their own maintenance and repairs, leading to significant cost savings and a deeper understanding of their motorcycle's mechanics.
General Information:
Included
Engine Right Side:
Included
Engine Removal Installation:
Included
Engine Bottom End Transmission:
Included
Electrical System:
Included
Estimated Page Count:
N/A (Digital Download)
Type:
Service Repair Manual
Download Type:
Instant Download
Engine Systems:
Detailed coverage of top-end (cylinder, piston, ring, cylinder head), right-side components (clutch, transmission gears), engine removal/installation procedures, and bottom-end assembly including crankshaft, bearings, and transmission components.
Fuel And Cooling:
Comprehensive information on the fuel system (carburetor tuning, fuel delivery) and cooling system (liquid cooling system components, coolant flow, radiator).
Chassis And Drivetrain:
Includes detailed sections on wheels, tires, final drive (chain and sprockets), brakes (hydraulic system, pad replacement, caliper service), suspension (forks, shock absorber, linkages), steering assembly, and frame inspection and repair.
Electrical System:
Coverage of the motorcycle's electrical system, including wiring diagrams, lighting, ignition system, and battery maintenance.
Maintenance And Tune-Up:
Step-by-step instructions for routine maintenance, tune-ups, and adjustments, enabling owners to perform tasks themselves.
Repair And Rebuild:
Detailed procedures for component repair, troubleshooting common issues, and complete engine and chassis rebuilds.
Diagnostics:
Guidance on diagnosing problems within various systems, supported by troubleshooting charts and symptom-based solutions.
Depth:
Extremely comprehensive, covering everything from basic pre-ride checks and fluid changes to complex engine teardowns, transmission overhauls, and suspension rebuilds. Suitable for both novice and experienced mechanics.
Compatibility:
All Versions of Windows & Mac
Reader Requirement:
Adobe PDF Reader
Zoom Capability:
High (Zoomable on computer for clear viewing of details)
Binding:
N/A (Digital PDF)
Paper Quality:
N/A (Digital PDF)
Type:
Liquid-cooled, two-stroke, single-cylinder
Bore X Stroke Kx85:
48.5 mm x 45.8 mm
Type:
Liquid-cooled, two-stroke, single-cylinder
Bore X Stroke Kx100:
52.5 mm x 45.8 mm
Displacement Kx100:
99 cc
Power Delivery:
Known for strong mid-range and top-end power delivery typical of aggressive motocross engines.
Carburetor Kx85:
Keihin PWK28 (typical, may vary slightly by year)
Carburetor Kx100:
Keihin PWK34 (typical, may vary slightly by year)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Oil Mixture:
2-stroke engine oil pre-mix (specific ratio detailed in manual, typically 20:1 or 32:1)
Type:
6-speed constant mesh, return type
Type:
Kawasaki Motorcycle Gear Oil SAE 80W-90 (or equivalent)
Capacity:
Approximately 0.65 Liters (Manual will specify exact amount and level check procedure)
Length:
Approx. 1845 mm (72.6 in)
Width:
Approx. 770 mm (30.3 in)
Height:
Approx. 1105 mm (43.5 in)
Length:
Approx. 1845 mm (72.6 in)
Width:
Approx. 770 mm (30.3 in)
Height:
Approx. 1105 mm (43.5 in)
Curb Weight Kx85:
Approx. 73 kg (161 lbs)
Curb Weight Kx100:
Approx. 75 kg (165 lbs)
Fuel Capacity:
5.0 L (1.3 US gal)
Safety Standards:
Designed to meet relevant motorcycle safety standards for off-road competition use. Not street legal without modifications.
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Suspension:
Long-travel, adjustable suspension (front forks and rear shock) for superior control and handling over rough terrain.
Ergonomics:
Designed for rider control and confidence with well-positioned handlebars and footpegs.
Features:
N/A (These are competition dirt bikes with minimal electronic features focused on performance and durability, not infotainment systems.)
Features:
N/A (No driver assistance systems are present on these models.)
Features:
N/A (No integrated connectivity features.)
Oil Change Transmission:
Recommended every 5-10 hours of riding or annually. Specific guidance in manual.
Air Filter Cleaning:
After every few rides or as conditions dictate. Crucial for engine longevity.
Spark Plug Check:
Check and clean/replace every 10-15 hours of riding or as performance degrades.
Top End Rebuild:
Recommended between 20-40 hours of hard use, depending on riding style and maintenance. Manual provides detailed procedures.
Coolant:
Kawasaki All-Season Motorcycle Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors)
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Power Valve Cleaning:
Carbon buildup on the power valve mechanism can lead to performance issues. Regular cleaning is recommended.
Clutch Wear:
Clutch plates can wear out, especially with aggressive riding. Manual details inspection and replacement.
Suspension Seals:
Fork seal leaks can occur with heavy use. Regular inspection and maintenance are advised.
Manual Utility:
The manual serves as an indispensable guide for identifying correct part numbers and understanding their assembly order for all repair and maintenance tasks.
Kawasaki Offroad:
Kawasaki has a long-standing and successful history in motocross and off-road racing, with the KX line being a dominant force for decades.
Kx85 Kx100 Line:
The KX85 and KX100 represent a crucial step in Kawasaki's mini-motocross lineup, serving as developmental bikes for aspiring racers and continuing a legacy of performance-oriented small-displacement dirt bikes.
Manufacturing Region:
Typically manufactured in Japan.
Kx Line Legacy:
The Kawasaki KX line consistently receives praise and awards in the motocross community for its performance, handling, and race-winning capabilities.
Rider Feedback:
Highly regarded by young riders and their parents for ease of use, adjustability, and competitive performance in its class.
