Category:
Motocross / Off-Road Competition Motorcycle
Target Audience:
Amateur and professional motocross racers, off-road enthusiasts, and mechanics working on Kawasaki KX85 motorcycles.
Competitors:
Yamaha YZ85, KTM 85 SX, Suzuki RM85, Honda CR85R.
Vehicle Attributes:
Powerful two-stroke engine, agile chassis, competitive suspension, and racing-oriented design.
Manual Value Proposition:
Provides comprehensive, factory-authorized repair and maintenance information essential for keeping the KX85 performing at its peak.
Engine:
Complete overhaul procedures for the 85cc two-stroke engine, including top-end rebuilds (piston, rings, cylinder, head), bottom-end rebuilds (crankshaft, connecting rod, bearings, seals), cooling system, and lubrication.
Transmission:
Detailed instructions for transmission inspection, disassembly, assembly, clutch operation, and gearbox maintenance, including gear inspection and replacement.
Fuel System:
Carburetor specifications, adjustment procedures (jetting, idle speed, float height), fuel line routing, fuel tank maintenance, and fuel filter replacement.
Ignition System:
Spark plug specifications, ignition timing procedures, CDI unit diagnostics, and stator/pickup coil testing.
Cooling System:
Radiator maintenance, coolant specifications, water pump inspection and repair, thermostat operation, and troubleshooting cooling system issues.
Suspension:
Front fork (upside-down telescopic) and rear shock absorber (Uni-Trak system) disassembly, assembly, seal replacement, oil level and viscosity specifications, spring rate information, and adjustment procedures for compression and rebound damping.
Brakes:
Front and rear hydraulic disc brake system maintenance, including caliper inspection and rebuild, master cylinder service, brake pad replacement, brake fluid specifications and bleeding procedures, and rotor specifications.
Electrical System:
Wiring diagrams, lighting system maintenance, battery specifications and charging procedures, fuse identification and replacement, and troubleshooting common electrical faults.
Chassis And Frame:
Frame inspection, swingarm maintenance, steering head bearing service, and general chassis component checks.
Wheels And Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, and spoke tension adjustment.
Maintenance:
Detailed routine maintenance procedures including oil changes (gearbox oil), filter cleaning/replacement, chain adjustment, spark plug checks, air filter servicing, and general lubrication points.
Troubleshooting:
Comprehensive diagnostic charts and symptom-based troubleshooting guides for common issues like starting problems, poor performance, overheating, and electrical faults.
Repair And Rebuild:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly for all major systems, including complete engine rebuilds.
Adjustments:
Procedures for clutch lever adjustment, throttle cable adjustment, brake lever adjustment, suspension adjustments, and carburetor adjustments.
Specifications:
Torque specifications for all fasteners, critical component measurements, and clear visual aids for assembly and disassembly.
Depth:
Comprehensive. Covers everything from basic rider maintenance to full engine and transmission rebuilds, including advanced diagnostics and component-level repairs.
Type:
Liquid-cooled, 2-stroke, reed-valve induction
Bore X Stroke:
48.5 mm x 45.8 mm
Compression Ratio:
9.9:1 (typical, may vary by year/spec)
Horsepower:
Approx. 24-26 HP (at crankshaft, varies by year/tune)
Torque:
Approx. 12-13 lb-ft (at crankshaft, varies by year/tune)
Carburetor:
Keihin PWK28 (28mm slide valve carburetor)
Fuel Type:
Unleaded gasoline, 91 octane or higher recommended
Fuel Oil Mixture:
50:1 ratio with high-quality 2-stroke oil (e.g., JASO FD or API TC rated)
Engine Top End:
Piston and ring inspection/replacement recommended every 40-60 hours of race time, or as indicated by performance degradation.
Gearbox Oil Change:
Every 15-20 hours of riding, or more frequently under hard use.
Air Filter Cleaning:
After every ride or every few hours of use, depending on conditions.
Spark Plug Replacement:
As needed, check gap before every few rides. NGK BR10EG or equivalent is common.
Engine Oil:
Kawasaki Gear Oil 10W-40 (or equivalent API GL-4 or GL-5 specification for manual transmissions).
Coolant:
High-quality motorcycle coolant, a 50/50 mix of distilled water and ethylene glycol-based antifreeze.
Brake Fluid:
DOT 4 or DOT 5.1 brake fluid.
Common Wear Items:
Clutch plates, piston rings, crank bearings, wheel bearings, fork seals, and suspension linkage bearings are common wear items on high-performance 2-stroke motocross bikes.
Carburetor Fouling:
Can occur if incorrect fuel/oil mixture is used or if the bike sits for extended periods without fuel stabilizer.
Clutch Slippage:
Can result from worn clutch plates or improper clutch cable adjustment.
