🏷️ Basic Information

Make:

Kawasaki

Model:

KX60

Model Code:

KX60-B13

Year:

1997

Vin Prefix:

JKB00130xxxxxxxxx (Example - VIN structure for this era/model needs verification)

👋 Introduction

Market Position:

The Kawasaki KX60 was a popular entry-level motocross bike designed for young riders, often serving as a stepping stone to larger KX models. It competed in a segment with other small-displacement dirt bikes from manufacturers like Yamaha (YZ60/80), Suzuki (RM60/80), and Honda (CR60/80).

Competitive Analysis:

The KX60's strengths lay in its robust build, reliable two-stroke engine, and agile handling, making it a favored choice for novice riders developing their skills. Its direct competition came from similarly styled and priced machines from other Japanese manufacturers.

Key Features:

Compact and lightweight design, potent two-stroke engine for its class, adjustable suspension for rider comfort and control, durable construction suitable for off-road use.

📋 Manual Details

Coverage:

Comprehensive repair and maintenance for Kawasaki KX60-B13 1997

Page Count:

252

Manual Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Systems Covered:

Engine, Transmission, Chassis, Electrical System, Suspension, Brakes, Fuel System, Cooling System, Lubrication System, Bodywork, Wheels and Tires, Tools and Special Equipment

Engine Mechanical:

Complete disassembly, assembly, inspection, and repair of the engine, including cylinder, piston, crankshaft, connecting rod, bearings, seals, and gaskets. Includes detailed torque specifications for all fasteners.

Fuel And Ignition:

Carburetor service, adjustment, and troubleshooting; ignition system testing and component identification (CDI, spark plug, coil).

Transmission And Drivetrain:

Gearbox disassembly, inspection, and assembly; clutch operation and adjustment; chain and sprocket wear and replacement guidelines.

Suspension And Steering:

Front fork disassembly, seal replacement, fluid levels and types, rear shock absorber inspection and service, steering system maintenance and bearing checks.

Brakes And Wheels:

Front disc brake system maintenance (caliper, master cylinder, pads, rotor), rear drum brake service, wheel bearing inspection and replacement, tire information.

Electrical System:

Basic electrical system overview, wiring diagrams (if included), component identification (lights, ignition coil), troubleshooting common electrical faults.

Chassis And Body:

Frame inspection, body panel removal and installation, seat, handlebars, and footpeg servicing.

Lubrication System:

Details regarding engine lubrication, including oil types, mixing ratios, and maintenance of the lubrication system components.

Procedures Included:

Maintenance, Adjustments, Removal, Installation, Disassembly, Assembly, Troubleshooting, Inspection, Repair, Torque Specifications, Wear Limits, Diagnostic Procedures

Troubleshooting Guide:

Extensive troubleshooting section covering common starting problems, engine performance issues, transmission glitches, and braking concerns, with systematic diagnostic steps.

Specifications Charts:

Comprehensive lists of all essential specifications, including tightening torques, wear limits, fluid capacities, jetting information, and electrical resistance values.

Pictorial Diagrams:

Detailed exploded diagrams and pictorial illustrations for every major component and system, aiding in identification and reassembly.

Safety Precautions:

Includes explicit NOTES, CAUTIONS, and WARNINGS to be followed alongside standard safety procedures to prevent personal injury and avoid damage to the vehicle or compromise of its safety.

Fastener Information:

Emphasis on using correct OEM fasteners, with specific torque values provided for service assembly and installation procedures. Guidance on replacing fasteners with identical part numbers is also included.

Technical Depth:

Detailed step-by-step procedures with illustrations, exploded diagrams, and factory specifications for complete rebuilds and advanced diagnostics. Suitable for professional mechanics and experienced DIY enthusiasts.

Rebuild Procedures:

Provides complete, detailed instructions for engine and transmission rebuilds, suitable for those undertaking major overhauls.

Special Tool References:

References and illustrations for specialized tools required for specific repair operations, ensuring correct procedures and preventing damage.

Diy Vs Professional:

Written in simple, precise language to be easily understood by both experienced mechanics and DIY enthusiasts, enabling satisfactory after-service for customers.

Manual Completeness:

100% complete and intact, with no missing or corrupt pages/sections.

📊 Manual Specifications

File Format:

PDF

Digital Delivery:

Instant download available upon payment completion, ensuring immediate access to repair information.

Print Quality:

Printable high-resolution pages

Binding Type:

Digital Download (PDF)

Paper Type:

N/A (Digital File)

Compatibility:

Windows, Mac, Linux OS (Requires Adobe Reader)

⚙️ Engine Specifications

Engine Type:

Liquid-Cooled, 2-Stroke, Single-Cylinder

Displacement:

59.8 cc

Bore X Stroke:

43.0 x 41.6 mm

Compression Ratio:

7.7 : 1 (Approximate, verification needed)

Ignition:

CDI (Capacitor Discharge Ignition)

Cooling System:

Liquid-cooled engine, with detailed procedures for coolant checks, flushing, and replacement. Radiator and associated plumbing maintenance is covered.

Horsepower:

Approximately 13-15 HP (Estimation based on similar models, exact figures may vary and are in the manual)

Torque:

Torque specifications available within the manual

Carburetor:

Manufacturer and model specific, e.g., Keihin (details in manual)

Fuel Type:

Unleaded gasoline with 2-stroke oil mixture (e.g., 32:1 or 40:1 ratio specified in manual)

🔧 Transmission

Transmission Type:

6-Speed Manual Transmission

Clutch Type:

Wet, Multiple-Disc

Final Drive:

Chain Drive (Gear ratio details in manual)

📐 Dimensions

Overall Length:

Approx. 1645 mm (64.8 in)

Overall Width:

Approx. 730 mm (28.7 in)

Overall Height:

Approx. 985 mm (38.8 in)

Wheelbase:

Approx. 1135 mm (44.7 in)

Dry Weight:

Approx. 64 kg (141.1 lbs)

🛡️ Safety Features

Safety Ratings:

N/A (Off-road vehicle, no road safety ratings apply)

Active Features:

Responsive braking system (front disc, rear drum), predictable handling.

Passive Features:

Durable frame construction, ergonomic seating position for rider control.

💡 Technology Features

Infotainment Features:

N/A (Basic motocross bike, no infotainment systems).

Driver Assistance Features:

N/A (No electronic driver assistance systems).

Connectivity Features:

N/A (No connectivity features).

🔧 Maintenance

Recommended Maintenance Intervals:

Detailed periodic maintenance chart provided in the manual, including checks for air filter, spark plug, chain tension, brake operation, and fluid levels (e.g., gearbox oil, coolant).

Periodic Maintenance Chart:

A structured chart detailing recommended service intervals for regular inspections, adjustments, and replacements to ensure optimal performance and longevity. This includes pre-ride checks and more in-depth servicing.

Customer Satisfaction Link:

Following the specified service schedules and maintenance requirements is emphasized for obtaining maximum customer satisfaction and the best performance from the vehicle.

Engine Oil Type:

High-quality 2-stroke oil mixed with gasoline at specified ratio (e.g., SAE 10W-30 or SAE 10W-40 for gearbox oil, specified in manual).

Coolant Type:

Ethylene glycol-based, permanent type antifreeze (details in manual).

Gearbox Oil Capacity:

Specified capacity for the transmission/gearbox oil, critical for proper lubrication. Manual will specify the exact type and quantity.

Common Issues:

Common issues for small two-stroke motocross bikes of this era include carburetor jetting adjustments due to environmental factors, wear on clutch components, exhaust port carbon buildup, and potential for top-end wear if not properly maintained. The manual will provide specific troubleshooting for these.

Preventative Maintenance Tips:

Includes recommendations on preventing common issues, such as proper engine break-in procedures, cleaning the air filter regularly, and maintaining correct tire pressure.

📚 Vehicle History

Brand Heritage:

Kawasaki has a long-standing reputation in motocross and off-road racing, with the KX line being a flagship series known for performance and innovation.

Model Evolution:

The KX60 was part of Kawasaki's lineage of small-displacement dirt bikes, evolving from earlier models and laying the groundwork for subsequent KX65 and KX80/85 models.

Model Designation Explanation:

The 'B13' designation typically refers to a specific manufacturing year or sub-model variation within the KX60 line, indicating the 1997 model year. The 'KX60' itself has a history of serving as an entry-level motocross platform.

Production Years:

Mid-1980s to early 2000s (exact start/end for B13 variant needs confirmation from broader Kawasaki history).