Kawasaki KX60-B15 1999 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Kawasaki Model: KX60 Model Code: KX60-B15 Year: 1999 Vehicle Type: Off-Road Motorcycle Category: Motocross/Dirt Bike 👋 Introduction Market Position Market Segment: Entry-level/youth motocross segment. Target...

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类型: Motorcycle

斯库: 433157

标签: 1999 Kawasaki KX Series KX60-B15 Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Model Code:

KX60-B15

Year:

Vehicle Type:

Off-Road Motorcycle

Category:

Motocross/Dirt Bike

👋 Introduction

Market Position

Market Segment:

Entry-level/youth motocross segment.

Target Audience:

Young riders learning the fundamentals of motocross and off-road riding.

Competitive Analysis

Key Competitors:

Honda CR60/XR60, Yamaha YZ60/PW50 (different class but similar entry point), Suzuki RM60.

Key Features

Vehicle Focus:

Simplicity, durability, ease of maintenance for young riders.

Manual Value Proposition:

Provides comprehensive, step-by-step guidance enabling owners to perform all necessary maintenance and repairs, fostering self-sufficiency and cost savings.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual

Language:

English

Format:

File Type:

Digital Download

Page Count:

Printability:

Compatibility:

Windows, Mac, Linux OS

Software Requirement:

Adobe Reader

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, assembly, inspection, and repair of all engine internal components (pistons, rings, crankshaft, connecting rod, cylinder, cylinder head, valves, etc.)

Engine Fuel System:

Carburetor (Mikuni VM series) adjustment, cleaning, overhaul, jetting; fuel tank and petcock service.

Engine Ignition System:

Ignition timing, spark plug specifications, CDI unit testing, troubleshooting.

Cooling System:

N/A (Air-cooled engine)

Exhaust System:

Exhaust pipe and silencer maintenance and repair.

Transmission System:

Clutch operation, adjustment, replacement; gear shifting mechanism, gearbox disassembly and assembly.

Drivetrain:

Chain and sprocket maintenance, adjustment, replacement.

Suspension Front:

Front fork (telescopic) disassembly, assembly, oil change, seal replacement, spring service.

Suspension Rear:

Rear shock absorber maintenance and adjustment, linkage system service.

Brakes Front:

Drum brake system inspection, adjustment, lining replacement.

Brakes Rear:

Drum brake system inspection, adjustment, lining replacement.

Wheels And Tires:

Spoke tensioning, wheel bearing service, tire replacement and mounting, rim repair.

Electrical System:

Lighting system (if applicable), wiring diagrams, battery maintenance (if applicable).

Frame And Bodywork:

Frame inspection and repair, handlebar, seat, fenders, plastics removal and installation.

Controls:

Throttle cable adjustment, brake lever and clutch lever service, shifter and footpeg maintenance.

Procedures Included

Maintenance:

Periodic maintenance checks, lubrication points, cleaning procedures, filter replacement.

Troubleshooting:

Diagnosing common problems with symptoms and solutions, identifying root causes.

Disassembly Assembly:

Step-by-step instructions for removing and reinstalling all major components and sub-assemblies.

Repair:

Detailed guidance on repairing worn or damaged parts, including machining or replacement procedures.

Adjustment:

Precise instructions for adjusting various systems (clutch, brakes, carburetor, chain slack, etc.) to factory specifications.

Inspection:

Guidelines for inspecting components for wear, damage, or proper function.

Specifications:

Comprehensive listing of all critical technical data, including measurements, tolerances, and torque values.

Special Tools:

Identification and usage instructions for specific Kawasaki service tools required for certain procedures.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine rebuilds and chassis overhauls.

Illustrations:

Pictorial diagrams, exploded views, drawings, and photos for clear procedural guidance.

Diagnostic Information:

Included for troubleshooting common issues.

📊 Manual Specifications

File Format

File Format:

File Quality:

High-resolution, printable pages.

Text Searchability:

Implied by PDF format, allowing for text search.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download, printable on user's choice of paper)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, single-cylinder

Displacement:

59.7 cc

Bore X Stroke:

44.0 x 40.6 mm

Cooling Method:

Air-cooled

Ignition:

CDI (Capacitor Discharge Ignition)

Performance

Horsepower:

Approx. 8.0 HP @ 7,500 rpm (estimated)

Torque:

Not explicitly stated, but characteristic of small displacement 2-strokes.

Fuel System

Carburetor Model:

Mikuni VM14SC

Fuel Type:

Unleaded gasoline (2-stroke oil mixture required)

Fuel Mixture Ratio:

Refer to manual for specific ratio (typically 20:1 or 32:1)

Fuel Tank Capacity:

3.0 L (0.8 US gal)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain drive

📐 Dimensions

Exterior

Overall Length:

1530 mm (60.2 in)

Overall Width:

740 mm (29.1 in)

Overall Height:

955 mm (37.6 in)

Wheelbase:

1090 mm (42.9 in)

Ground Clearance:

230 mm (9.1 in)

Seat Height:

735 mm (28.9 in)

Weights

Dry Weight:

64 kg (141.1 lbs)

🛡️ Safety Features

Ratings

Safety Standard:

N/A (Off-road vehicle, not subject to road safety regulations)

Active Features

Braking System:

Drum brakes front and rear, designed for off-road use.

Suspension Capability:

Provides rider control over varied terrain.

Passive Features

Chassis Construction:

Robust frame designed for off-road durability.

Manual Warnings:

Emphasizes DANGER, CAUTION, and NOTE remarks for safety during repair and operation.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic off-road motorcycle)

Driver Assistance

Driver Assistance Features:

N/A (Basic off-road motorcycle)

Connectivity

Connectivity Features:

N/A (Basic off-road motorcycle)

🔧 Maintenance

Service Intervals

Oil Change:

Refer to manual for specific intervals, but generally every 10-15 hours of use for the gearbox oil.

Air Filter Cleaning:

Recommended after every few rides or as per manual instructions, crucial for engine longevity.

Spark Plug Replacement:

Recommended at specified hours or when fouled.

Chain Lubrication Adjustment:

Regularly, typically every ride or every few hours of operation, and adjusted for proper slack.

Fluid Specifications

Gearbox Oil:

Refer to manual for specific grade (e.g., SAE 80W API GL-4 or GL-5).

Fork Oil:

Refer to manual for specific type and viscosity (e.g., Showa SS-8 or equivalent).

2 Stroke Oil:

High-quality 2-stroke motorcycle oil, mixed with gasoline at the specified ratio.

Known Issues

Clutch Slippage:

Can occur with heavy use or worn clutch plates/springs.

Carburetor Fouling:

Common in off-road use due to dirt ingress or incorrect jetting.

Fork Seal Leaks:

A common issue on dirt bikes due to constant suspension articulation and potential impacts.

Chain Wear:

Requires regular maintenance to prevent premature wear and potential failure.

📚 Vehicle History

Brand Heritage

Kawasaki Motorsports:

Kawasaki has a long and successful history in off-road racing, particularly in motocross and supercross with its KX line.

Model Evolution

Kx60 Lineage:

The KX60 was part of Kawasaki's youth motocross lineup, evolving from earlier models and serving as a stepping stone to larger displacement bikes.

Production

Production Period:

The KX60 was produced throughout the 1980s and 1990s, with the B15 being a specific iteration of the 1999 model year.

🏆 Awards & Recognition

Recognitions

Model Achievements:

As a youth model, specific awards are less common; its success is measured by rider development and enjoyment.

Ratings

Durability Rating:

Generally considered durable and reliable for its class when properly maintained, as indicated by the need for a comprehensive service manual.

Certifications

Manual Certification:

Meets comprehensive service documentation standards for effective repair and maintenance.