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Kawasaki KX100-D4 2004 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: KX100 Year: 2004 Variant Code: D4 Codes Oem Manual Identifier: 99969-1117 👋 Introduction Market Position Segment: Competitive entry-level to intermediate motocross racing machine...
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🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX100
Year:
2004
Variant Code:
D4
Codes
Oem Manual Identifier:
99969-1117
👋 Introduction
Market Position
Segment:
Competitive entry-level to intermediate motocross racing machine for junior riders.
Target Audience:
Young motocross racers, track day enthusiasts, and mechanics working on this specific model.
Competitive Analysis
Key Competitors Era:
Honda CR85R, Yamaha YZ85, Suzuki RM85, KTM 85 SX.
Key Features
Engine Type:
Potent 99cc liquid-cooled two-stroke engine.
Suspension Type:
High-performance Kayaba USD (Upside-Down) front forks and rear shock absorber.
Brakes:
Powerful front and rear hydraulic disc brakes.
Transmission:
Smooth-shifting 6-speed transmission.
Manual Value Proposition:
Provides comprehensive, factory-authorized repair and maintenance information, ensuring accuracy and completeness for owners and technicians.
📋 Manual Details
Coverage Areas
Primary Focus:
Factory Service Repair
Vehicle Types Covered:
Off-road Motorcycle / Motocross
Specific Models Covered:
Kawasaki KX100-D4 (2004 Model Year)
Page Count
Estimated Pages:
Hundreds (exact count not specified, but comprehensive)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine disassembly, inspection, repair, and reassembly for the 99cc two-stroke engine.
Fuel System:
Carburetor (Mikuni VM24) tuning, cleaning, rebuilding, specifications, and troubleshooting.
Ignition System:
CDI ignition system, stator, ignition coil, spark plug specifications, and testing.
Cooling System:
Liquid-cooled system, radiator, water pump, coolant specifications, and maintenance.
Transmission Drivetrain:
Clutch operation, adjustment, and replacement; gearbox inspection, repair, and lubrication.
Chassis Frame:
Frame inspection, alignment, and repair; sub-frame specifications.
Suspension Front:
Front fork (Kayaba USD) disassembly, rebuilding, oil specifications, service intervals, and adjustment procedures.
Suspension Rear:
Rear shock absorber (Kayaba) rebuilding, linkage lubrication, spring preload adjustment, and damping adjustments.
Braking System:
Front and rear hydraulic disc brake systems, caliper overhaul, master cylinder service, fluid specifications, and bleeding procedures.
Electrical System:
Lighting system, wiring diagrams, battery specifications, and fuse information.
Fuel Tank And Lines:
Fuel tank maintenance, fuel line inspection and replacement.
Exhaust System:
Exhaust pipe and silencer inspection and maintenance.
Wheels And Tires:
Wheel bearing service, tire pressure recommendations, and rim specifications.
Procedures Included
Preventive Maintenance:
Detailed scheduled maintenance procedures, lubrication points, and component checks.
Troubleshooting:
Systematic troubleshooting guides for common performance issues, starting problems, and operational faults.
Repair And Rebuild:
Step-by-step instructions for complete component disassembly, repair, and reassembly.
Engine Rebuild:
Piston replacement, ring gap setting, cylinder honing, crankshaft inspection, and sealing.
Carburetor Adjustment:
Idle speed, main jet, pilot jet, needle position, and air screw adjustments.
Suspension Tuning:
Sag adjustment, compression and rebound damping tuning for optimal performance.
Brake Bleeding:
Proper procedure for removing air from hydraulic brake lines.
Wiring Diagram Interpretation:
Detailed electrical schematics for diagnosis and repair.
Technical Depth
Depth:
Comprehensive, factory-level detail suitable for professional technicians and advanced DIY mechanics.
Diagnostic Capabilities:
Includes troubleshooting charts and diagnostic procedures for identifying faults.
Specification Tables:
Extensive tables of critical torque values, clearances, fluid capacities, and electrical resistances.
Component Diagrams:
Exploded view diagrams for easy identification and assembly/disassembly reference.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text content for easy navigation (standard for factory PDFs).
Print Quality
Printability:
Designed for printing, allowing users to print the entire manual or specific sections.
Binding Type
Binding Type:
N/A (Digital PDF Download)
Paper Type
Paper Type:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
99 cc (6.0 cubic inches)
Bore X Stroke:
52.5 mm x 45.8 mm (2.07 in x 1.80 in)
Compression Ratio:
9.7:1 (Dynamic)
Valve System:
Reed valve induction, KIPS (Kawasaki Integrated Powervalve System)
Performance
Horsepower Estimated:
Approximately 23-25 HP (at crankshaft, typical for this class)
Torque Estimated:
Approximately 12-14 lb-ft (at crankshaft, typical for this class)
Fuel System
Carburetor:
Mikuni VM24, single
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Fuel Mixture:
50:1 ratio of gasoline to 2-stroke engine oil
🔧 Transmission
Standard
Type:
Constant-mesh, 6-speed return
Clutch:
Wet, multi-disc
Final Drive:
Chain drive, RK520ML, 136 links (standard)
Optional
Gear Ratios:
1st: 2.467 (37/15), 2nd: 1.800 (27/15), 3rd: 1.400 (21/15), 4th: 1.133 (17/15), 5th: 0.917 (22/24), 6th: 0.750 (21/28)
Features
Lubrication:
Manual specifies gearbox oil, likely Kawasakii's own branded oil or equivalent SAE 10W-30 API SE/SF.
📐 Dimensions
Exterior
Overall Length:
1825 mm (71.9 in)
Overall Width:
760 mm (29.9 in)
Overall Height:
1150 mm (45.3 in)
Wheelbase:
1250 mm (49.2 in)
Ground Clearance:
305 mm (12.0 in)
Seat Height:
850 mm (33.5 in)
Weights
Curb Weight:
73 kg (161 lbs) - (Dry weight often quoted for dirt bikes, check specific manual for exact figure)
Fuel Capacity:
5.7 Liters (1.5 US gal)
Cooling System Capacity:
0.7 Liters (0.7 US qt)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety is assessed through specific regulations and rider training, not typical consumer ratings like cars).
Active Features
Braking System:
Dual hydraulic disc brakes provide strong stopping power.
Suspension Stability:
High-quality suspension contributes to rider control and stability.
Passive Features
Ergonomics:
Designed for rider control and balance during off-road riding.
Frame Design:
Rigid frame for predictable handling.
💡 Technology Features
Infotainment
Infotainment System:
N/A (This is a competition motocross bike; no infotainment features present).
Driver Assistance
Driver Assistance Features:
N/A (No electronic driver assistance systems on this model).
Connectivity
Connectivity Features:
N/A (No digital connectivity features).
Engine Management
Power Valve System:
KIPS (Kawasaki Integrated Powervalve System) electronically controlled exhaust port timing for improved low-end torque and peak power delivery.
🔧 Maintenance
Service Intervals
Oil Change Engine:
Check oil level before every ride. Recommended replacement/top-up of 2-stroke oil mixture is as needed.
Air Filter Cleaning:
Clean after every few rides, or more frequently in dusty conditions. Replace as needed.
Spark Plug Check And Replacement:
Inspect and clean spark plug periodically. Replace if fouled or worn. (Gap specification: 0.6-0.7 mm).
Chain Lubrication And Adjustment:
Lubricate chain every 3-5 rides. Adjust slack to 15-25 mm (0.6-1.0 in).
Brake Pad Inspection:
Inspect brake pads for wear at regular intervals (e.g., every 5-10 rides depending on usage).
Suspension Service:
Fork oil change every 20-30 hours of use. Rear shock linkage lubrication every 10-15 hours.
Top End Rebuild:
Recommended every 20-40 hours of racing use, depending on severity of use and maintenance quality. (Piston and ring replacement).
Fluid Specifications
Engine Oil 2 Stroke:
API-TC rated 2-stroke motorcycle oil (e.g., Bel-Ray, Motul, Yamalube, Castrol) mixed at 50:1 ratio.
Gearbox Oil:
SAE 10W-30 API SE/SF or higher (Check manual for specific Kawasaki recommendation, often GL-4 is acceptable).
Coolant:
Permanent type radiator coolant (antifreeze) mixed with distilled water at a 50:50 ratio.
Brake Fluid:
DOT 3 or DOT 4 brake fluid (Check manual for specific DOT rating).
Known Issues
Clutch Wear:
Clutch plates can wear out relatively quickly under aggressive use. Proper adjustment and oil quality are key.
Carburetor Jetting:
Requires careful jetting for optimal performance across different altitudes and temperatures. KIPS system adjustment is also crucial.
Suspension Seals:
Fork and shock seals can leak over time, requiring periodic replacement to maintain suspension performance and prevent internal damage.
Power Valve Carbon Buildup:
The KIPS power valve mechanism can accumulate carbon deposits, affecting engine performance and requiring cleaning.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycle Division:
Kawasaki Heavy Industries has a long-standing reputation for performance-oriented motorcycles, particularly in off-road racing.
Model Evolution
Kx Series Lineage:
The KX100 is part of a lineage of successful Kawasaki motocross bikes, evolving from smaller displacement models to offer more power and advanced features.
Kx100 Development:
The KX100 model class typically caters to junior riders transitioning from 85cc classes, offering a step up in performance and handling.
Production
Production Period:
The KX100 has been in continuous production for many years, with the D4 designation specifically for the 2004 model year.
Manufacturing Location:
Typically manufactured in Japan by Kawasaki Heavy Industries.
🏆 Awards & Recognition
Recognitions
Motocross Championships:
While specific awards for the 2004 KX100 model are not documented as stand-alone items, the KX lineage has a strong track record of success in amateur and professional motocross racing series globally.
Ratings
Industry Reviews:
Reviews from the era often lauded the KX100 for its strong engine performance and capable chassis, making it a popular choice for aspiring racers.