Kawasaki KX60 1998-2010 Workshop Service Manual for Repair

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This workshop service manual covers the KX60, an off-road motorcycle designed for youth motocross and sport riding, produced between 1998 and 2010. As part of the renowned KX lineage, this...

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Taper: Motorcycle

Distributeur:

UGS: 73220

Mots clés: 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Kawasaki KX Series KX60 Motorcycle Motorcycles

Variantes de produits

Description

This workshop service manual covers the KX60, an off-road motorcycle designed for youth motocross and sport riding, produced between 1998 and 2010. As part of the renowned KX lineage, this entry-level to intermediate dirt bike is celebrated for its ease of handling and the reputation for durable off-road machinery. The KX60 features a 59.6 cc air-cooled, 2-stroke engine, a 6-speed manual transmission, and front and rear disc brakes, making it a capable platform for developing young riders' skills. This comprehensive 250-page English-language manual provides detailed guidance on all aspects of the KX60. It includes step-by-step procedures for routine maintenance, troubleshooting common issues, and complete repairs for all major systems, including the engine, transmission, chassis, suspension, brakes, fuel, and electrical systems. With in-depth explanations, diagrams, and technical specifications, this manual is an essential resource for owners, mechanics, and technicians to ensure the optimal performance, reliability, and longevity of their KX60.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Type:

Off-road Motorcycle (Dirt Bike)

Codes

Engine Codes:

Likely KSR110 engine family variants (specific codes not provided in source data)

👋 Introduction

Market Position

Market Segment:

Entry-level to intermediate youth motocross/off-road sportbike.

Competitive Analysis

Competitors:

Yamaha YZ80/85, Suzuki RM80/85, Honda CR80/85.

Key Features

Ease Of Use:

Designed for younger riders, emphasizing ease of handling and maintenance.

Durability:

Kawasaki's reputation for robust off-road machinery.

📋 Manual Details

Coverage Areas

Years Covered:

1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF (Downloadable)

📖 Manual Coverage

Systems Covered

Engine:

Disassembly, assembly, inspection, adjustment, troubleshooting of engine components (carburetor, ignition, cooling, lubrication, etc.)

Transmission:

Service, inspection, and repair of the gearbox and clutch assembly.

Chassis And Suspension:

Front fork, rear shock absorber, swingarm, linkage, steering system, wheel bearings, and related components.

Brakes:

Front and rear brake systems, including hydraulic lines, master cylinders, calipers, and pads.

Electrical System

Electrical System:

Ignition system, lighting, battery, wiring diagrams, and component testing.

Fuel System

Fuel System:

Fuel tank, fuel lines, and carburetor service and adjustment.

Bodywork And Frame

Bodywork And Frame:

Frame inspection, fairings, seat, and other body components.

Procedures Included

Maintenance:

Routine maintenance checks, lubrication, adjustments, and periodic service intervals.

Troubleshooting:

Systematic diagnostic procedures for common problems and failures.

Repair:

Step-by-step instructions for disassembly, repair, and reassembly of all major components.

Installation:

Procedures for installing new or replacement parts.

Technical Depth

Technical Depth:

Comprehensive, from basic adjustments to complete engine rebuilds, with detailed explanations and diagrams.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

Printable (high resolution implied by comprehensive coverage)

Binding Type

Binding Type:

Digital (N/A for PDF)

Paper Type

Paper Type:

Digital (N/A for PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, single-cylinder

Displacement:

59.6 cc (typical for KX60 models)

Bore X Stroke:

43.0 mm x 41.6 mm (typical)

Cooling System:

Air-cooled

Performance

Horsepower:

Approx. 9-10 HP (estimated, exact figures vary by year and tuning)

Torque:

Not explicitly provided, but tuned for low-end torque suitable for youth riders.

Fuel System

Carburetor:

Mikuni VM15SC (typical)

Fuel Type:

Unleaded gasoline mixed with 2-stroke oil (ratio specified in manual)

🔧 Transmission

Standard

Transmission Type:

6-speed manual

Features

Clutch Type:

Wet multi-disc

📐 Dimensions

Exterior

Overall Length:

Approx. 1620 mm (typical)

Overall Width:

Approx. 740 mm (typical)

Overall Height:

Approx. 1015 mm (typical)

Weights

Dry Weight:

Approx. 63 kg (typical)

Wheelbase:

Approx. 1130 mm (typical)

🛡️ Safety Features

Ratings

Safety Features:

Standard motocross safety features; emphasis on rider skill development.

Active Features

Braking System:

Front and rear disc brakes for reliable stopping power.

💡 Technology Features

Infotainment

Infotainment System:

None (This is a dedicated off-road racing motorcycle).

Driver Assistance

Driver Assistance Features:

None (This is a dedicated off-road racing motorcycle).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Specific interval for gearbox oil change will be detailed in the manual, typically after initial break-in and then periodically.

Spark Plug Replacement:

Regular inspection and replacement based on usage and condition, as per manual recommendations.

Air Filter Cleaning:

Frequent cleaning and/or replacement of the air filter is critical for 2-stroke engines, especially in dusty off-road conditions.

Fluid Specifications

Gear Oil:

Manual will specify SAE 10W-30 or SAE 10W-40 API GL-4 transmission oil for the gearbox.

2 Stroke Oil:

High-quality 2-stroke motorcycle oil, premix or injection system, with specific ratio recommendations in the manual.

Known Issues

Clutch Wear:

Common in high-performance off-road bikes; subject to wear due to aggressive riding. Manual will detail inspection and replacement.

Carburetor Fouling:

Can occur due to improper fuel/oil mixture or debris; manual provides cleaning and adjustment procedures.

Suspension Seals:

Front fork and rear shock seals can wear over time, leading to leaks; manual covers seal replacement and suspension service.

📚 Vehicle History

Brand Heritage

Kawasaki Motorsports:

Kawasaki has a long and successful history in motorcycle racing, particularly in motocross and supercross.

Model Evolution

Kx Lineage:

The KX60 is part of Kawasaki's esteemed KX line of motocross bikes, designed to introduce young riders to the sport.

Production

Production Period:

The KX60 was produced for a significant period, with the 1998-2010 range representing a substantial portion of its later production.

🏆 Awards & Recognition

Recognitions

Awards:

The KX60 has historically been recognized as a capable and reliable entry-level motocross bike, fostering many young racing careers.