Segment:
Motocross/Off-Road Competition (Mini-Cycle)
Target Audience:
Enthusiasts, amateur racers, mechanics, and DIY individuals focused on the KX100 platform.
Key Competitors:
Yamaha YZ85, Suzuki RM85, Honda CR85R (all relevant for the era)
Vehicle Focus:
Performance-oriented, lightweight, powerful for its class, designed for competitive motocross racing.
Manual Value Proposition:
Provides essential, factory-backed information to maintain and repair the KX100, ensuring optimal performance and longevity.
Primary Coverage:
Complete service and repair for Kawasaki KX100 model year 2005
Secondary Coverage:
Adjustment, troubleshooting, maintenance, disassembly, assembly, component checks
Estimated Page Count:
Approximately 300-400 pages (typical for factory service manuals of this era)
Type:
Factory Service Repair Manual
Format:
Likely Digital (PDF) for sales purposes, mirroring original factory documentation
Engine:
Complete engine disassembly, assembly, tuning, troubleshooting, power valve system, cooling system (if applicable, though likely air-cooled), lubrication
Transmission:
Gearbox disassembly, assembly, inspection, shift mechanism, clutch operation and service
Fuel System:
Carburetor (Mikuni VM series) tuning, cleaning, overhaul, fuel tank and petcock service
Ignition System:
CDI ignition system, spark plug specifications, testing, troubleshooting
Suspension:
Front fork (Kayaba/Showa) service, oil levels, seal replacement, rear shock absorber service, linkage lubrication and inspection
Brakes:
Front and rear brake system service, hydraulic fluid type and bleeding, pad replacement, caliper service
Electrical System:
Basic lighting circuit, wiring diagrams, troubleshooting common electrical faults
Chassis And Bodywork:
Frame inspection, seat, handlebars, footpegs, body panel removal and installation
Routine Maintenance:
Oil changes, chain adjustment, air filter cleaning, spark plug replacement, general lubrication
Disassembly And Assembly:
Step-by-step instructions for major component removal and reinstallation
Troubleshooting:
Diagnostic charts for common problems and their solutions
Rebuilds:
Detailed procedures for engine and transmission overhauls
Adjustments:
Carburetor jetting, ignition timing (if adjustable), clutch and brake lever adjustments
Diagnostic Charts:
Includes troubleshooting flowcharts based on symptoms to aid in problem diagnosis.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine rebuilds and advanced troubleshooting.
Image Resolution:
High resolution for clear diagrams and text
Text Searchability:
Likely includes OCR for searchable text
Original Binding:
Wire-bound or perfect bound (for physical copies)
Original Paper:
Durable, high-quality paper suitable for workshop environments
Coverage Scope:
A complete factory service manual, providing all necessary information for mechanical operation, diagnosis, and repair.
Type:
2-stroke, single-cylinder
Displacement:
99 cc (9.9 cubic inches)
Stroke:
45.8 mm (1.803 in)
Cooling System:
Liquid-cooled (though some earlier models were air-cooled, 2005 is liquid-cooled)
Power Valve System:
KIPS (Kawasaki Integrated Powervalve System)
Compression Ratio:
Typically around 8.6:1 for this era's model (as per factory specs).
Horsepower:
Approx. 25-27 HP (estimated, specific figures vary based on tuning and dyno)
Torque:
Approx. 12-14 lb-ft (estimated)
Carburetor Type:
Mikuni VM28SS (single downdraft)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Fuel Mix Ratio:
Typically 50:1 pre-mix ratio for 2-stroke oil
Length:
Approx. 72.6 inches (1845 mm)
Width:
Approx. 31.7 inches (805 mm)
Height:
Approx. 44.7 inches (1135 mm)
Wheelbase:
Approx. 50.4 inches (1280 mm)
Dry Weight:
Approx. 165 lbs (75 kg)
Fuel Tank Capacity:
1.4 US gallons (5.5 Liters)
Crash Safety:
Not applicable for competition motorcycles; safety depends on rider skill and protective gear.
Braking System:
Hydraulic disc brakes (front and rear)
Protective Gear:
Manual emphasizes rider use of helmet, boots, gloves, and body protection.
Oil Change Frequency:
Recommended after every 15-20 hours of riding or as specified in the manual for optimal engine life.
Air Filter Cleaning:
Frequent cleaning is crucial, ideally after every few rides or in dusty conditions.
Chain Lubrication And Adjustment:
Lubricate every 5-10 hours of riding, adjust slack as needed based on manual specifications.
Spark Plug Replacement:
Inspect every 20-30 hours, replace as needed or per manual schedule.
Transmission Oil Type:
KawiAPI GL-4, SAE 80 gear oil (e.g., Kawasaki Genuine Gear Oil or equivalent)
Coolant Type:
High-quality ethylene glycol-based coolant with demineralized water (50/50 mix recommended)
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Transmission Oil Capacity:
Approx. 0.75 Liters (750 ml) (refer to manual for exact capacity)
Common Wear Items:
Piston rings, spark plug, clutch plates, chain and sprockets, wheel bearings, fork seals.
Engine Tuning Sensitivity:
2-stroke engines, particularly performance-oriented ones like the KX100, can be sensitive to carburetor jetting and air filter cleanliness.
Kawasaki Motocross:
Kawasaki has a long and successful history in motocross, dating back to the 1960s, with many championship-winning models.
Kx Lineage:
The KX100 is part of the continuously developed KX line, evolving from the smaller KX80. Key upgrades in this generation included improved suspension and revised engine tuning.
Manufacturing Location:
Japan
Production Period:
The KX100 was produced in various iterations for many years, with significant updates in the late 1990s and early 2000s.
