Target Audience:
DIY enthusiasts and professional mechanics for the Kawasaki KX60-B7.
Value Proposition:
Provides essential, detailed information for maintaining and repairing a classic youth motocross bike, enabling cost-effective ownership.
Accessibility:
Instant PDF download offers immediate access to repair information.
Usability:
Designed for ease of understanding with simple explanations, diagrams, and photos.
Engine:
Complete engine disassembly, assembly, inspection, and adjustment procedures for the KX60 engine.
Transmission:
Gearbox inspection, disassembly, assembly, and adjustment, including clutch and shift mechanism.
Fuel System:
Carburetor inspection, cleaning, adjustment, and troubleshooting. Fuel tank, petcock, and fuel lines.
Ignition System:
CDI ignition system testing, spark plug specifications, and troubleshooting.
Cooling System:
Air cooling system maintenance and inspection.
Suspension:
Front fork (telescopic) inspection, seal replacement, oil levels, and rear shock absorber maintenance.
Brakes:
Front and rear drum brake system inspection, adjustment, lining wear limits, and cable adjustments.
Electrical System:
Basic electrical component testing, wiring diagrams (implied), lighting, and kill switch.
Chassis And Frame:
Frame inspection, steering head bearing adjustment and replacement.
Wheels And Tires:
Spoke tension inspection, rim runout checks, and tire pressure recommendations.
Controls:
Throttle, clutch, and brake lever adjustments and cable maintenance.
Exhaust System:
Exhaust pipe and silencer inspection and maintenance.
Maintenance:
Routine maintenance tasks, lubrication points, and checks.
Troubleshooting:
Diagnostic procedures for common issues, fault finding based on symptoms.
Repair:
Step-by-step repair instructions for all major vehicle components.
Disassembly And Assembly:
Detailed guides for taking apart and reassembling various parts and systems.
Adjustments:
Precise instructions for adjusting clutches, brakes, throttle, and other controls.
Special Tool Usage:
Identification and usage instructions for specialized tools required for specific procedures.
Depth:
Comprehensive, from basic maintenance to detailed component overhaul and troubleshooting.
Print Quality:
Printable with high fidelity; text and diagrams remain clear.
Searchability:
PDF format allows for text searching of keywords.
Binding:
Digital (PDF download), no physical binding.
Paper Type:
N/A (Digital format), but printable on standard paper.
Type:
Two-stroke, single-cylinder, reed valve induction.
Displacement:
57.7 cm³ (3.53 cu in)
Bore X Stroke:
43.0 x 40.6 mm (1.69 x 1.60 in)
Horsepower:
Approximately 10-12 HP (typical for this class and era, specific manual data may vary).
Carburetor Model:
Mentioned as having detailed adjustment procedures, likely a Mikuni VM series.
Fuel Type:
Unleaded gasoline mixed with 2-stroke oil (pre-mix).
2-Stroke Oil Type:
Specified as approved lubricants, typically JASO FB or FC rated two-stroke oil.
Dry Weight:
Approximately 60 kg (132 lbs) - typical for this model, manual may specify exact.
Overall Length:
Approx. 1535 mm (60.4 in) - typical.
Overall Width:
Approx. 770 mm (30.3 in) - typical.
Overall Height:
Approx. 930 mm (36.6 in) - typical.
Wheelbase:
Approx. 1065 mm (41.9 in) - typical.
Ground Clearance:
Approx. 230 mm (9.1 in) - typical.
Seat Height:
Approx. 710 mm (28.0 in) - typical.
Oil Change 2Stroke Premix:
Regularly check and top off 2-stroke oil in the fuel mixture as per riding conditions.
Air Filter Cleaning:
Frequent cleaning and oiling of the air filter, especially in dusty conditions.
Spark Plug Check:
Periodic inspection and cleaning/replacement of the spark plug.
Chain Lubrication Tension:
Regular cleaning, lubrication, and tension adjustment of the drive chain.
Brake Adjustment:
Check and adjust brake free play regularly to ensure proper function.
Suspension Service:
Periodic inspection of fork seals and shock absorber for leaks; potential fork oil change as per manual.
Transmission Oil Type:
Gear oil, typically SAE 80 API GL-4 (specific viscosity may be detailed in the manual).
Fork Oil Type:
Specific fork oil weight (e.g., 10W) and level will be detailed.
Carburetor Clogging:
Common issue in older bikes due to fuel varnish; requires regular cleaning and proper fuel storage.
Air Filter Maintenance:
Neglecting air filter maintenance can lead to premature engine wear.
Brake Wear:
Drum brake linings wear over time and require adjustment or replacement.
Chain Wear:
Drive chain and sprockets wear and require periodic replacement.
Carburetor Jetting:
The manual will provide specific jet sizes, needle settings, and float height for proper fuel mixture.
Ignition Timing:
Specifications for ignition timing will be provided for performance and correct operation.
Tightening Torques:
Crucial torque values for critical fasteners will be listed to ensure proper assembly and prevent damage.
Wear Limits:
Specific wear limits for engine components (e.g., piston, cylinder bore) will be detailed for diagnosis.
Kawasaki Legacy:
Kawasaki has a long-standing reputation in off-road and motocross racing with its KX series.
Kx60 Lineage:
The KX60 was a foundational model in Kawasaki's youth motocross lineup, evolved from earlier models and serving as a stepping stone to larger displacement bikes.
Production Era:
The KX60 model was produced throughout the late 1980s and into the 1990s.
