Target Audience:
Mechanics and DIY persons.
Purpose:
To provide data, characteristics, instructions, and methodology for repair interventions.
Manual Advantage:
Detailed explanations, pictorial diagrams, step-by-step procedures for efficient repair.
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).
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.
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.
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.
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)
Horsepower:
Approximately 10-12 HP (estimated based on similar models)
Torque:
N/A (Specific torque figures typically not published for this class of bike)
Carburetor:
Mikuni VM14SC
Fuel Type:
Unleaded gasoline with 2-stroke oil mixture (e.g., 20:1 or 32:1 depending on manufacturer recommendation)
Oil Type:
API TC or JASO FD certified 2-stroke oil
Safety Ratings:
N/A (Not applicable to off-road motorcycles in the same way as street vehicles)
Braking System:
Drum brakes front and rear.
Suspension Type:
Telescopic front fork, single rear shock absorber.
Protective Gear Recommendation:
Manual emphasizes rider safety and the need for protective gear, though not a 'feature' of the bike itself.
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.
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.
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.
Manufacturer Heritage:
Kawasaki Heavy Industries has a long history of motorcycle manufacturing, particularly in off-road racing with its KX line.
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 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)