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Kawasaki KX85 KX100 2010 Full Service Repair Manual

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The Kawasaki KX85 and KX100 are high-performance, lightweight, two-stroke off-road competition motorcycles designed for youth and amateur motocross racing. Building on Kawasaki's rich heritage in motocross, these models offer powerful...
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Tipo: Motorcycle
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SKU: 99656
Kawasaki KX85 KX100 2010 Full Service Repair Manual
The Kawasaki KX85 and KX100 are high-performance, lightweight, two-stroke off-road competition motorcycles designed for youth and amateur motocross racing. Building on Kawasaki's rich heritage in motocross, these models offer powerful engines with displacements of 84 cc for the KX85 and 99 cc for the KX100, both featuring liquid-cooled, single-cylinder configurations. Known for their agile handling, robust construction, and ability to achieve championship titles, these motorcycles are engineered to provide riders with a competitive edge on the track. Their design prioritizes rider control and feedback, making them a popular choice in their segment. This comprehensive service repair manual provides detailed coverage for the Kawasaki KX85 and KX100 models from 2010. It is designed to assist owners, mechanics, and technicians in performing full service, repair, maintenance, rebuilds, refurbishment, and restoration. The manual covers all essential systems, including the engine, transmission, chassis, electrical components, and fuel system, with in-depth instructions for procedures such as routine servicing, component replacement, and complete overhauls. It also includes troubleshooting guidance and technical specifications, ensuring the vehicle remains in optimal condition and performance.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX85 & KX100
Year:
2010
Codes
Product Code Identifier:
Likely internal reference for the manual's publisher, not a Kawasaki VIN prefix.
👋 Introduction
Market Position
Segment:
Competition Motocross (MX) / Off-Road Motorcycles.
Competitive Analysis
Competitors:
Honda CR85R/CR125R, Yamaha YZ85/YZ125, Suzuki RM85/RM125, KTM 85 SX/125 SX.
Key Features
Vehicle Focus:
High-performance, lightweight, two-stroke off-road racing motorcycles designed for youth and amateur competition.
Manual Purpose
Utility:
To empower owners and mechanics with the knowledge to maintain, repair, and optimize the performance of their Kawasaki KX85 and KX100 motorcycles.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full service, repair, maintenance, rebuild, refurbishment, restoration.
Page Count
Estimated Pages:
Estimated 300-500+ pages (typical for comprehensive service manuals).
Manual Type
Type:
Full Service Repair Manual
Language
Language:
English (Assumed, standard for most aftermarket manuals).
Format
Format:
Likely Digital (PDF) based on typical online sales, but could be printed.
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, tuning, top-end, bottom-end, lubrication, cooling (if applicable), fuel delivery.
Transmission:
Clutch, gearbox, shift mechanism, lubrication.
Chassis:
Frame, subframe, suspension (forks, shock absorber), steering, wheels, tires, braking system (front and rear), chain drive, footpegs, controls.
Electrical:
Ignition system, lighting, wiring diagrams, component testing, troubleshooting.
Fuel System:
Carburetor (type and model specific), fuel lines, fuel tank.
Procedures Included
Maintenance:
Regular servicing, oil changes, filter replacements, spark plug service, chain adjustment, brake bleeding, air filter cleaning/replacement.
Repair:
Component replacement (e.g., pistons, rings, valves, bearings, seals, cables, brake pads, levers), common wear item repair.
Troubleshooting:
Diagnostic procedures for common problems, identification of faulty components.
Rebuilds:
Complete engine rebuild, transmission overhaul, suspension fork rebuild.
Technical Depth
Depth:
Comprehensive, covering everything from basic routine maintenance to complete engine and chassis overhauls. Includes detailed diagrams and specifications.
📊 Manual Specifications
File Format
Digital Format:
PDF (likely), potentially with searchable text and high-resolution images.
Print Quality
Image Resolution:
High resolution for diagrams and illustrations, ensuring clarity.
Binding Type
Binding:
N/A (if PDF); If printed, typically spiral-bound for lay-flat use in a workshop.
Paper Type
Paper Quality:
N/A (if PDF); If printed, usually on durable, glossy or semi-gloss paper.
⚙️ Engine Specifications
Primary Engine
Type:
Two-stroke, liquid-cooled, single-cylinder.
Kx85 Displacement:
84 cc
Kx100 Displacement:
99 cc
Bore Stroke Kx85:
48.5 mm x 45.8 mm
Bore Stroke Kx100:
52.5 mm x 45.8 mm
Performance
Horsepower Kx85 Approx:
~23-25 HP (at crankshaft, estimate for model year)
Horsepower Kx100 Approx:
~27-29 HP (at crankshaft, estimate for model year)
Torque Kx85 Approx:
~11-12 lb-ft (estimate for model year)
Torque Kx100 Approx:
~13-14 lb-ft (estimate for model year)
Fuel System
Carburetor Kx85:
Keihin PWK28 (typical specification)
Carburetor Kx100:
Keihin PWK35 (typical specification)
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended for optimal performance.
Two Stroke Oil Mix:
Specified ratio (e.g., 50:1 or 40:1) with high-quality, JASO FD certified two-stroke premix oil.
🔧 Transmission
Standard
Type:
6-speed constant mesh, return shift.
Optional
Options:
N/A (Performance motocross bikes typically have a single transmission configuration).
Features
Clutch:
Wet, multi-disc, manual operation.
Gear Ratios:
Specific gear ratios for each speed would be detailed in the manual.
Final Drive:
Chain drive.
📐 Dimensions
Exterior
Length Kx85:
~1770 mm (approx. 69.7 in)
Length Kx100:
~1835 mm (approx. 72.2 in)
Width Overall:
~730 mm (approx. 28.7 in)
Height Seat Kx85:
~1045 mm (approx. 41.1 in)
Height Seat Kx100:
~1075 mm (approx. 42.3 in)
Ground Clearance:
Varies, typically over 300mm (approx. 12 in).
Wheelbase Kx85:
~1220 mm (approx. 48.0 in)
Wheelbase Kx100:
~1255 mm (approx. 49.4 in)
Weights
Curb Weight Kx85:
~70 kg (approx. 154 lbs) (without fuel)
Curb Weight Kx100:
~73 kg (approx. 161 lbs) (without fuel)
Fuel Tank Capacity:
~5.0 Liters (approx. 1.3 US gal)
🛡️ Safety Features
Ratings
Safety Certification:
Designed for closed-course competition. Not street legal. Safety features are performance-oriented.
Active Features
Braking System:
Hydraulic disc brakes front and rear for powerful and controlled stopping.
Suspension Tuning:
Adjustable suspension components (rebound, compression) allow for tuning to rider preference and track conditions, enhancing control.
Passive Features
Chassis Design:
Rigid perimeter frame for stability and rider feedback.
Ergonomics:
Designed for optimal rider positioning and control during aggressive riding.
💡 Technology Features
Infotainment
Features:
N/A (Pure performance motocross bike, no infotainment features).
Driver Assistance
Features:
N/A (No electronic driver assistance systems).
Connectivity
Features:
N/A (No electronic connectivity features).
🔧 Maintenance
Service Intervals
Oil Change:
Every 10-15 hours of riding, or annually. Detailed checks recommended more frequently.
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions. Critical for two-stroke engine longevity.
Spark Plug Inspection:
Every 5-10 hours of riding. Replace as needed.
Chain Tension:
Check and adjust before every ride, or as needed based on wear.
Fluid Specifications
Engine Oil Type:
Dedicated two-stroke engine oil (JASO FD certified recommended). Capacity is very small and specific to the injection system.
Transmission Oil Type:
SAE 10W-30 API SE, SF, SG or SH engine oil (refer to manual for precise API rating and type).
Transmission Oil Capacity:
Approximately 0.65 Liters (refer to manual for exact capacity and fill level check procedure).
Coolant Type:
Permanent type anti-freeze coolant, mixed 50/50 with distilled water.
Known Issues
Common Wear Items:
Clutch plates, piston rings, top-end bearings, wheel bearings, steering stem bearings, chain and sprockets, brake pads, fork seals.
Carburetor Tuning:
Sensitivity to jetting changes based on altitude, temperature, and modifications. Requires proper tuning for optimal performance and engine health.
Two Stroke Maintenance:
Requires diligent adherence to oil mixing, air filter cleaning, and spark plug maintenance to prevent premature engine wear and seizure.
📚 Vehicle History
Brand Heritage
Kawasaki Motocross:
Kawasaki has a long and storied history in motocross racing, with legendary models like the KX series achieving numerous championship titles.
Model Evolution
Kx Lineage:
The KX85 and KX100 are direct descendants of Kawasaki's successful larger displacement KX motocross bikes, scaled down for youth riders and smaller classes.
Production
Manufacturing Location:
Typically manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Motocross Titles:
The KX85 and KX100 platforms have historically been highly competitive and successful in amateur and professional motocross racing classes, contributing to Kawasaki's overall racing prestige.
Ratings
Industry Reviews:
Consistently praised for their powerful engines, agile handling, and robust construction in industry reviews and rider feedback.
Certifications
Performance Standards:
Meets or exceeds the performance standards expected for competitive motocross machinery in its class.
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