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Kawasaki KX60-B5 1989 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Kawasaki Model: KX60-B5 Year: 1989 Type: Dirt Bike / Motocross Codes Internal Model Code: KX60-B5 👋 Introduction Market Position Target Audience: Mechanics and DIY persons....
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Type: Motorcycle
Vendor:
Sku: 433069
Kawasaki KX60-B5 1989 Workshop Service Manual for RepairKawasaki KX60-B5 1989 Workshop Service Manual for RepairKawasaki KX60-B5 1989 Workshop Service Manual for RepairKawasaki KX60-B5 1989 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KX60-B5
Year:
1989
Type:
Dirt Bike / Motocross
Codes
Internal Model Code:
KX60-B5
👋 Introduction
Market Position
Target Audience:
Mechanics and DIY persons.
Purpose:
To provide data, characteristics, instructions, and methodology for repair interventions.
Competitive Analysis
Manual Advantage:
Detailed explanations, pictorial diagrams, step-by-step procedures for efficient repair.
Key Features
Ease Of Use:
Specially prepared for simple explanations, making complex tasks accessible to less experienced personnel.
Accessibility:
Viewable on any computer, zoomable, and printable.
Information Density:
Contains special notes, important points, service data, and precautions.
Safety Emphasis:
Highlights the importance of using correct tools and following safety procedures (DANGER, CAUTION, NOTE).
📋 Manual Details
Coverage Areas
Manual Title:
Workshop Service Manual for Repair
Applicable Models:
Kawasaki KX60-B5
Applicable Years:
1989
Page Count
Total Pages:
252
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
File Format:
PDF
Distribution Method:
Instant Download
📖 Manual Coverage
Systems Covered
Engine:
Complete disassembly, assembly, inspection, repair, and adjustment of the engine and its components.
Fuel System:
Carburetor overhaul, fuel line inspection, fuel tank maintenance.
Cooling System:
Air-cooled system checks and maintenance.
Ignition System:
Ignition timing, spark plug specifications, CDI unit testing.
Transmission:
Clutch operation, gear shifting mechanism, transmission oil checks and replacement.
Chassis:
Frame inspection, suspension fork overhaul, shock absorber adjustment and service.
Brakes:
Drum brake inspection, adjustment, and component replacement for front and rear.
Wheels And Tires:
Tire pressure recommendations, wheel bearing service, spoke tension checks.
Electrical System:
Wiring diagrams, lighting system checks, fuse replacement.
Bodywork And Controls:
Handlebar, levers, footpegs, seat removal and installation, plastic panel maintenance.
Procedures Included
Maintenance:
Periodic maintenance checks, lubrication points, filter replacement, chain adjustment.
Troubleshooting:
Diagnostic procedures for common performance issues, starting problems, and component failures.
Repair:
Step-by-step instructions for the removal, disassembly, cleaning, inspection, assembly, and installation of all major components.
Adjustments:
Detailed instructions for adjusting clutch, brakes, carburetor idle, and suspension settings.
Rebuilds:
Comprehensive guidance for engine rebuilds, including piston, cylinder, and crankshaft service.
Technical Depth
Depth:
Highly detailed, comprehensive, bumper-to-bumper coverage.
Diagrams:
Includes exploded diagrams, pictorial diagrams, drawings, and photos for clarity.
Special Tools:
References special service tool numbers and illustrates their usage.
Wear Limits:
Includes wear limits and allowable limits for critical components.
Torque Values:
Provides specific tightening torque values for fasteners.
Diagnostics:
Includes diagnostic information for troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Compatibility:
Windows, Mac, Linux OS
Software Requirement:
Adobe Reader
Print Quality
Printability:
All pages are printable.
Page Orientation:
Portrait (implied for typical service manuals)
Binding Type
Binding:
Digital (PDF Download)
Paper Type
Paper Quality:
N/A (Digital Format)
Completeness
Completeness Statement:
100% Complete and Intact, no missing/corrupt pages/sections.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Two-stroke, single-cylinder
Displacement:
59 cc (3.6 cu in)
Bore X Stroke:
43.0 x 41.6 mm (1.7 x 1.6 in)
Cooling System:
Forced air cooling
Compression Ratio:
6.8:1 (approximate)
Ignition:
CDI (Capacitor Discharge Ignition)
Performance
Horsepower:
Approximately 10-12 HP (estimated based on similar models)
Torque:
N/A (Specific torque figures typically not published for this class of bike)
Fuel System
Carburetor:
Mikuni VM14SC
Fuel Type:
Unleaded gasoline with 2-stroke oil mixture (e.g., 20:1 or 32:1 depending on manufacturer recommendation)
Lubrication
Oil Type:
API TC or JASO FD certified 2-stroke oil
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh, return shift
Clutch Type:
Wet, multi-disc
Features
Gear Ratios:
Manual will contain specific gear ratios for each speed.
Final Drive:
Chain drive
📐 Dimensions
Exterior
Overall Length:
Approx. 1,535 mm (60.4 in)
Overall Width:
Approx. 740 mm (29.1 in)
Overall Height:
Approx. 920 mm (36.2 in)
Wheelbase:
Approx. 1,075 mm (42.3 in)
Ground Clearance:
Approx. 215 mm (8.5 in)
Weights
Dry Weight:
Approx. 54 kg (119 lbs)
Curb Weight:
N/A (Typically not specified for this model)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Not applicable to off-road motorcycles in the same way as street vehicles)
Active Features
Braking System:
Drum brakes front and rear.
Suspension Type:
Telescopic front fork, single rear shock absorber.
Passive Features
Protective Gear Recommendation:
Manual emphasizes rider safety and the need for protective gear, though not a 'feature' of the bike itself.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic off-road motorcycle with no infotainment features)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Manual will specify intervals for transmission oil based on usage hours or mileage.
Spark Plug Check:
Regular checks and cleaning/replacement recommended in the manual.
Air Filter Cleaning:
Frequent cleaning/replacement recommended, especially in dusty conditions.
Fluid Specifications
Transmission Oil Type:
Refer to manual for specific grade (e.g., SAE 80 or 90 gear oil)
Fuel Mixture Ratio:
Typically 20:1 or 32:1 depending on oil manufacturer and conditions. Manual will confirm.
Known Issues
Common Wear Items:
Clutch plates, piston rings, air filter, chain and sprockets, wheel bearings.
Carburetor Issues:
Clogged jets from fuel residue, worn floats, or incorrect adjustments can lead to poor running.
Suspension Wear:
Fork seals can leak, and rear shock damping may degrade over time, requiring seals and fluid service.
📚 Vehicle History
Brand Heritage
Manufacturer Heritage:
Kawasaki Heavy Industries has a long history of motorcycle manufacturing, particularly in off-road racing with its KX line.
Model Evolution
Kx Lineage:
The KX60 was a popular entry-level youth motocross bike, part of Kawasaki's dedicated KX racing series, designed to introduce young riders to the sport.
Production
Production Period:
The KX60 model was produced through the late 1980s and early 1990s, with the 'B5' designation specifically for the 1989 model year.
Manufacturing Location:
Japan (typical for Kawasaki motorcycles of this era)
🏆 Awards & Recognition
Recognitions
Awards And Recognitions:
N/A (Specific awards for this model year are not readily available, focus is on its utility as a competitive entry-level bike)
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