Years Covered:
2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Product Name:
Kawasaki KX100 2001-2010 Service Repair Manual
Category:
Competition Motocross / Dirt Bike
Competitors:
Yamaha YZ100, Suzuki RM100, Honda CR100 (models within similar displacement and competition class).
Model Focus:
Designed for performance-oriented riders in the 100cc motocross class, known for its aggressive powerband and agile handling.
Manual Benefit:
Empowers owners and technicians with the knowledge to perform all necessary maintenance and repairs, maximizing performance and longevity.
Engine Service:
Complete overhaul, top-end rebuild, bottom-end service, carburetor tuning, cooling system service.
Chassis Service:
Suspension (forks, shock), steering system, wheel and tire maintenance, brake system service (front and rear).
Electrical System:
Ignition system, lighting, wiring diagrams, troubleshooting electrical faults.
Troubleshooting:
Diagnostic charts, common problems and solutions, fault finding procedures.
Type:
Service Repair Manual
Engine:
Two-stroke single-cylinder engine maintenance, disassembly, assembly, lubrication, cooling system.
Fuel System:
Carburetor (Keihin PWK series) tuning, jetting, cleaning, and rebuilding; fuel tank and lines.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox disassembly and assembly, chain and sprocket maintenance.
Suspension System:
Front fork servicing (oil changes, seal replacement), rear shock absorber maintenance and adjustment.
Brake System:
Hydraulic front and rear disc brake system service, pad replacement, caliper maintenance, bleeding procedures.
Electrical System:
Ignition system components (spark plug, coil), lighting circuits, battery maintenance, wiring diagrams for troubleshooting.
Frame Bodywork:
Frame inspection, body panel removal and installation, seat, handlebars, and footpeg maintenance.
Routine Maintenance:
Oil changes, filter cleaning/replacement, chain lubrication and adjustment, spark plug replacement, air filter cleaning.
Engine Repair:
Top-end rebuild (piston, rings, cylinder, head), crankshaft and connecting rod service, engine bearing replacement.
Carburetor Overhaul:
Detailed step-by-step instructions for carburetor disassembly, cleaning, inspection, and reassembly.
Suspension Rebuild:
Front fork seal and bushing replacement, fork oil level and type specifications, rear shock absorber servicing.
Brake Bleeding:
Proper procedures for flushing and bleeding the hydraulic brake system.
Troubleshooting Guides:
Systematic approaches to diagnose and resolve common performance issues, starting problems, and electrical faults.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and chassis rebuilds.
Type:
Two-stroke, single-cylinder, liquid-cooled
Displacement:
99 cc (6.0 cu in)
Bore X Stroke:
52.5 x 45.8 mm (2.07 x 1.80 in)
Compression Ratio:
9.7:1 (typical, may vary slightly by year)
Valves Timing:
Kawasaki Integrated Power-valve System (KIPS) - details covered in manual.
Horsepower:
Approx. 28-30 hp (at crankshaft, specific figures vary by year and dyno testing)
Torque:
Approx. 15-16 lb-ft (at crankshaft, specific figures vary)
Carburetor Model:
Keihin PWK35 (typically, specific jetting detailed in manual)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Oil Type:
2-stroke engine oil (e.g., Kawasaki KPS 2-Stroke Oil, Yamalube 2R, Motul 800 2T)
Fuel Oil Ratio:
50:1 (standard pre-mix, refer to manual for specific recommendations and break-in procedures)
Length:
Approx. 76.4 inches (1940 mm)
Width:
Approx. 31.5 inches (800 mm)
Height:
Approx. 47.2 inches (1200 mm)
Dry Weight:
Approx. 163 lbs (74 kg)
Curb Weight:
Approx. 177 lbs (80 kg) (with all fluids)
Front Tire Size:
70/100-17 40M
Rear Tire Size:
90/100-14 49M
Wheelbase:
Approx. 52.0 inches (1320 mm)
Oil Change Engine:
Refer to manual for specific interval based on riding hours/conditions (typically every 10-20 hours of hard use).
Air Filter Cleaning:
Clean after every few rides or as needed, especially in dusty conditions.
Chain Maintenance:
Lubricate and adjust chain tension every 5-10 riding hours or as needed.
Spark Plug Check:
Inspect and clean/replace as needed during top-end rebuilds or every 20-30 hours of riding.
Fork Oil Change:
Recommended every 20-40 hours of riding, depending on usage intensity.
Cooling System Coolant:
Kawasaki Super Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors) - 50% mix with distilled water. Capacity: 0.70 L.
Transmission Oil Capacity:
0.70 L (0.74 US qt)
Common Wear Items:
Clutch plates, piston rings, spark plug fouling (due to 2-stroke nature), suspension seals.
Carburetor Performance:
Can be sensitive to altitude and temperature changes, requiring periodic jetting adjustments. Gumming from fuel sitting is also common.
Kips System:
KIPS exhaust power valve system can accumulate carbon buildup, requiring cleaning for optimal performance.
Kawasaki Legacy:
Kawasaki has a long and successful history in motocross and off-road racing, with the KX line being a prominent part of that heritage.
Kx Lineage:
The KX100 has been a staple in Kawasaki's lineup for entry-level to intermediate motocross riders, evolving through various chassis and engine updates over the years. This generation represents a significant period of development in the 100cc class.
Manufacturing Location:
Japan (primary manufacturing location for Kawasaki motorcycles)
