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Kawasaki KX60-B15 1999 Workshop Service Manual for Repair
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🏷️ Basic Information Identification Make: Kawasaki Model: KX60 Model Code: KX60-B15 Year: 1999 Vehicle Type: Off-Road Motorcycle Category: Motocross/Dirt Bike 👋 Introduction Market Position Market Segment: Entry-level/youth motocross segment. Target...
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🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX60
Model Code:
KX60-B15
Year:
1999
Vehicle Type:
Off-Road Motorcycle
Category:
Motocross/Dirt Bike
👋 Introduction
Market Position
Market Segment:
Entry-level/youth motocross segment.
Target Audience:
Young riders learning the fundamentals of motocross and off-road riding.
Competitive Analysis
Key Competitors:
Honda CR60/XR60, Yamaha YZ60/PW50 (different class but similar entry point), Suzuki RM60.
Key Features
Vehicle Focus:
Simplicity, durability, ease of maintenance for young riders.
Manual Value Proposition:
Provides comprehensive, step-by-step guidance enabling owners to perform all necessary maintenance and repairs, fostering self-sufficiency and cost savings.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual
Language:
English
Format:
PDF
File Type:
Digital Download
Page Count:
252
Printability:
Yes
Compatibility:
Windows, Mac, Linux OS
Software Requirement:
Adobe Reader
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, assembly, inspection, and repair of all engine internal components (pistons, rings, crankshaft, connecting rod, cylinder, cylinder head, valves, etc.)
Engine Fuel System:
Carburetor (Mikuni VM series) adjustment, cleaning, overhaul, jetting; fuel tank and petcock service.
Engine Ignition System:
Ignition timing, spark plug specifications, CDI unit testing, troubleshooting.
Cooling System:
N/A (Air-cooled engine)
Exhaust System:
Exhaust pipe and silencer maintenance and repair.
Transmission System:
Clutch operation, adjustment, replacement; gear shifting mechanism, gearbox disassembly and assembly.
Drivetrain:
Chain and sprocket maintenance, adjustment, replacement.
Suspension Front:
Front fork (telescopic) disassembly, assembly, oil change, seal replacement, spring service.
Suspension Rear:
Rear shock absorber maintenance and adjustment, linkage system service.
Brakes Front:
Drum brake system inspection, adjustment, lining replacement.
Brakes Rear:
Drum brake system inspection, adjustment, lining replacement.
Wheels And Tires:
Spoke tensioning, wheel bearing service, tire replacement and mounting, rim repair.
Electrical System:
Lighting system (if applicable), wiring diagrams, battery maintenance (if applicable).
Frame And Bodywork:
Frame inspection and repair, handlebar, seat, fenders, plastics removal and installation.
Controls:
Throttle cable adjustment, brake lever and clutch lever service, shifter and footpeg maintenance.
Procedures Included
Maintenance:
Periodic maintenance checks, lubrication points, cleaning procedures, filter replacement.
Troubleshooting:
Diagnosing common problems with symptoms and solutions, identifying root causes.
Disassembly Assembly:
Step-by-step instructions for removing and reinstalling all major components and sub-assemblies.
Repair:
Detailed guidance on repairing worn or damaged parts, including machining or replacement procedures.
Adjustment:
Precise instructions for adjusting various systems (clutch, brakes, carburetor, chain slack, etc.) to factory specifications.
Inspection:
Guidelines for inspecting components for wear, damage, or proper function.
Specifications:
Comprehensive listing of all critical technical data, including measurements, tolerances, and torque values.
Special Tools:
Identification and usage instructions for specific Kawasaki service tools required for certain procedures.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine rebuilds and chassis overhauls.
Illustrations:
Pictorial diagrams, exploded views, drawings, and photos for clear procedural guidance.
Diagnostic Information:
Included for troubleshooting common issues.
📊 Manual Specifications
File Format
File Format:
PDF
File Quality:
High-resolution, printable pages.
Text Searchability:
Implied by PDF format, allowing for text search.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download, printable on user's choice of paper)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, single-cylinder
Displacement:
59.7 cc
Bore X Stroke:
44.0 x 40.6 mm
Cooling Method:
Air-cooled
Ignition:
CDI (Capacitor Discharge Ignition)
Performance
Horsepower:
Approx. 8.0 HP @ 7,500 rpm (estimated)
Torque:
Not explicitly stated, but characteristic of small displacement 2-strokes.
Fuel System
Carburetor Model:
Mikuni VM14SC
Fuel Type:
Unleaded gasoline (2-stroke oil mixture required)
Fuel Mixture Ratio:
Refer to manual for specific ratio (typically 20:1 or 32:1)
Fuel Tank Capacity:
3.0 L (0.8 US gal)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet, multiple-disc
Final Drive:
Chain drive
📐 Dimensions
Exterior
Overall Length:
1530 mm (60.2 in)
Overall Width:
740 mm (29.1 in)
Overall Height:
955 mm (37.6 in)
Wheelbase:
1090 mm (42.9 in)
Ground Clearance:
230 mm (9.1 in)
Seat Height:
735 mm (28.9 in)
Weights
Dry Weight:
64 kg (141.1 lbs)
🛡️ Safety Features
Ratings
Safety Standard:
N/A (Off-road vehicle, not subject to road safety regulations)
Active Features
Braking System:
Drum brakes front and rear, designed for off-road use.
Suspension Capability:
Provides rider control over varied terrain.
Passive Features
Chassis Construction:
Robust frame designed for off-road durability.
Manual Warnings:
Emphasizes DANGER, CAUTION, and NOTE remarks for safety during repair and operation.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic off-road motorcycle)
Driver Assistance
Driver Assistance Features:
N/A (Basic off-road motorcycle)
Connectivity
Connectivity Features:
N/A (Basic off-road motorcycle)
🔧 Maintenance
Service Intervals
Oil Change:
Refer to manual for specific intervals, but generally every 10-15 hours of use for the gearbox oil.
Air Filter Cleaning:
Recommended after every few rides or as per manual instructions, crucial for engine longevity.
Spark Plug Replacement:
Recommended at specified hours or when fouled.
Chain Lubrication Adjustment:
Regularly, typically every ride or every few hours of operation, and adjusted for proper slack.
Fluid Specifications
Gearbox Oil:
Refer to manual for specific grade (e.g., SAE 80W API GL-4 or GL-5).
Fork Oil:
Refer to manual for specific type and viscosity (e.g., Showa SS-8 or equivalent).
2 Stroke Oil:
High-quality 2-stroke motorcycle oil, mixed with gasoline at the specified ratio.
Known Issues
Clutch Slippage:
Can occur with heavy use or worn clutch plates/springs.
Carburetor Fouling:
Common in off-road use due to dirt ingress or incorrect jetting.
Fork Seal Leaks:
A common issue on dirt bikes due to constant suspension articulation and potential impacts.
Chain Wear:
Requires regular maintenance to prevent premature wear and potential failure.
📚 Vehicle History
Brand Heritage
Kawasaki Motorsports:
Kawasaki has a long and successful history in off-road racing, particularly in motocross and supercross with its KX line.
Model Evolution
Kx60 Lineage:
The KX60 was part of Kawasaki's youth motocross lineup, evolving from earlier models and serving as a stepping stone to larger displacement bikes.
Production
Production Period:
The KX60 was produced throughout the 1980s and 1990s, with the B15 being a specific iteration of the 1999 model year.
🏆 Awards & Recognition
Recognitions
Model Achievements:
As a youth model, specific awards are less common; its success is measured by rider development and enjoyment.
Ratings
Durability Rating:
Generally considered durable and reliable for its class when properly maintained, as indicated by the need for a comprehensive service manual.
Certifications
Manual Certification:
Meets comprehensive service documentation standards for effective repair and maintenance.