Model Designations:
KX85-A1, KX85-A2, KX85-A3, KX85-A4, KX85-A5, KX85-A6F, KX85-B1, KX85-B2, KX85-B3, KX85-B4, KX85-B5, KX85-B6F
Covered Years:
2001, 2002, 2003, 2004, 2005, 2006
Year Code Suffix Examples:
A1, A2, A3, A4, A5, A6F, B1, B2, B3, B4, B5, B6F
Segment:
Entry-level to intermediate motocross racing and off-road riding.
Key Competitors:
Yamaha YZ85, Suzuki RM85, Honda CR85.
Model Focus:
Performance-oriented, lightweight, powerful two-stroke engine for competitive riding.
Manual Utility:
Essential resource for owners and technicians to maintain and repair the KX85 across multiple model years.
Engine:
Full engine disassembly, assembly, tuning, and troubleshooting for two-stroke powerplants.
Transmission:
Gearbox removal, inspection, repair, and adjustment including clutch operation.
Chassis:
Frame, sub-frame, swingarm, linkage systems, and mounting points.
Suspension:
Front fork (USD - Upside Down) disassembly, seal replacement, fluid changes, and damping adjustments; rear shock absorber overhaul and adjustment.
Brakes:
Front and rear disc brake systems, caliper overhaul, master cylinder service, fluid bleeding, and pad replacement.
Fuel System:
Carburetor disassembly, cleaning, jetting, and adjustment; fuel tank and petcock service.
Ignition System:
CDI unit, spark plug, and wiring harness diagnostics.
Cooling System:
Liquid cooling system components, radiator, water pump, and thermostat service.
Exhaust System:
Exhaust pipe and silencer maintenance and installation.
Electrical System:
Basic lighting, kill switch, and wiring diagrams for essential functions.
Wheels Tires:
Wheel bearing replacement, spoke tensioning, and tire mounting/disassembly.
Maintenance:
Scheduled maintenance checks, lubrication, filter replacement, and adjustments.
Troubleshooting:
Diagnostic procedures for common operational problems and symptom-based fault finding.
Repair:
Step-by-step instructions for component replacement and repair of all major systems.
Overhaul:
Complete engine rebuild and major component overhaul procedures.
Disassembly Assembly:
Detailed guides for taking apart and putting back together all parts of the motorcycle.
Technical Data Provision:
Torque specifications, clearance measurements, and adjustment procedures.
Depth:
Comprehensive, covering basic maintenance to full engine and chassis rebuilds.
Diagram Quality:
High-quality diagrams, exploded views, and illustrations for clear guidance.
Instruction Style:
Step-by-step instructions, easy-to-read text sections.
Format Details:
Physical printed manual, not a digital file (PDF is not explicitly stated).
Quality:
High quality, designed for workshop use.
Binding:
Likely a robust binding suitable for workshop environments (e.g., spiral-bound or saddle-stitched).
Paper Quality:
Durable paper stock, resistant to grease and wear.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder, reed valve induction
Displacement:
84.5 cc (approx.)
Bore X Stroke:
48.5 x 45.8 mm (typical for this generation)
Compression Ratio:
9.7:1 (typical, may vary slightly by year)
Horsepower Approx:
20-25 HP (at crankshaft, estimated for the era)
Torque Approx:
12-15 Nm (estimated for the era)
Carburetor:
Keihin PWK35 (typical, may vary slightly by year)
Fuel Type:
Unleaded gasoline with proper 2-stroke oil premix (ratio specified in manual).
Ignition Type:
Digital CDI with electronic advance
Oil Change:
Regular oil changes for gearbox lubricant as specified in manual (e.g., every 10-20 hours of use).
Spark Plug:
Check/replace spark plug as per manual recommendations based on usage (e.g., every 20-40 hours).
Air Filter:
Frequent cleaning and oiling of the air filter is critical for engine longevity (recommendations based on riding conditions).
Top End Rebuild:
Piston, rings, and cylinder inspection/replacement typically recommended after 50-100 hours of hard use, depending on riding style and maintenance.
Gearbox Oil:
Specific SAE 80 or SAE 10W-30 API GL-4 gear oil (refer to manual for exact specification and capacity).
Coolant:
High-quality ethylene glycol-based coolant, mixed with distilled water (typically 50/50 ratio).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (check manual for specific type).
Carburetor Fouling:
Can be prone to clogging if fuel is not fresh or if the air filter is neglected.
Clutch Wear:
Clutch plates can wear prematurely with aggressive riding and improper clutch use.
Suspension Seals:
Front fork seal leaks can occur, requiring regular seal inspection and replacement.
Engine Top End Wear:
Consistent with any high-performance 2-stroke, the top end (piston, rings, cylinder) is a wear item requiring periodic attention.
Kawasaki Offroad Legacy:
Kawasaki has a long-standing history in motocross and off-road racing, with the KX line being a significant part of its performance-oriented identity.
Kx85 Development:
The KX85 evolved from earlier KX65/80 models, refining engine technology, suspension, and chassis design to meet competitive demands.
Manufacturing Location:
Typically Japan, though specific assembly locations can vary by market.
