Target Audience:
Mechanics and DIY enthusiasts for Kawasaki KX85-B4 2004
Purpose:
To provide data, characteristics, instructions, and methodology for repair interventions
Completeness:
100% complete and intact, no missing/corrupt pages/sections
Detail Level:
Most detailed, comprehensive step-by-step procedures, explanations, and pictorial diagrams
Readability:
Prepared so that explanation is very simple, easy to read reference book
Accessibility:
Instant Download, printable, viewable on any computer
Practicality:
Enables satisfactory after-services and maintenance even for comparatively new personnel
Engine:
Complete overhaul, disassembly, assembly, adjustments, specifications
Cooling System:
Radiator, hoses, coolant specifications, checking and draining
Fuel System:
Carburetor (rebuild, adjustment, cleaning), fuel tank, fuel lines, petcock
Ignition System:
Spark plug, ignition timing, CDI unit, coil testing
Exhaust System:
Muffler, expansion chamber, gasket replacement
Transmission:
Gearbox disassembly, assembly, gear inspection, clutch operation, fluid specifications
Clutch:
Clutch plates, springs, levers, adjustment, fluid maintenance
Suspension Front:
Fork disassembly, assembly, seal replacement, oil level and viscosity, spring preload, damping adjustments
Suspension Rear:
Shock absorber disassembly, rebuild, linkage lubrication, spring replacement, adjustments
Brakes Front:
Caliper overhaul, pad replacement, disc inspection, master cylinder maintenance, bleeding procedure
Brakes Rear:
Caliper overhaul, pad replacement, disc inspection, master cylinder maintenance, bleeding procedure
Wheels And Tires:
Spoke tensioning, bearing replacement, tire pressure specifications, wheel removal/installation
Electrical System:
Wiring diagrams, component testing, battery maintenance, lighting (if applicable), kill switch
Frame And Bodywork:
Frame inspection, plastic panel removal/installation, seat, handlebars, controls
Maintenance:
Periodic maintenance schedules, lubrication points, filter replacement
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting guides
Repair:
Detailed step-by-step instructions for component disassembly, repair, and reassembly
Installation:
Correct installation procedures for all components
Disassembly:
Comprehensive guide to taking components apart
Adjustment:
Carburetor, clutch, brakes, suspension, and other necessary adjustments
Checking:
Inspection procedures for wear, damage, and correct operation
Depth:
Comprehensive, from basic maintenance to full engine rebuilds and component overhauls
Diagrams:
Detailed illustrations, exploded diagrams, drawings, and photos
Special Tools:
Reference to specific special service tool numbers and usage illustrations
Specifications:
Service data, factory specifications, allowable limits, tightening torques
Precautions:
Important notes, precautions, special notes, DANGER/CAUTION/NOTE remarks for safety
Engine Type:
Two-stroke, single-cylinder
Displacement:
84 cm³ (5.1 cu in)
Stroke:
45.2 mm (1.78 in)
Carburetor:
Mikuni VM28SS (typical for this model)
Horsepower:
Approximately 22.3 HP @ 11,000 RPM (representative, varies by spec)
Torque:
Approximately 10.6 lb-ft @ 10,000 RPM (representative, varies by spec)
Fuel Type:
Unleaded gasoline
Fuel Mixture:
50:1 (Gasoline: 2-stroke oil) recommended
2 Stroke Oil Type:
API TC, JASO FD, or ISO-L-EGD rated 2-stroke oil
Oil Change Transmission:
Every 6-10 hours of operation or annually (refer to manual for specifics)
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions
Spark Plug Replacement:
As needed, typically every 20-30 hours of operation, depending on usage
Engine Oil Type:
High-quality 2-stroke premix oil (e.g., 50:1 ratio)
Coolant Type:
Ethylene glycol based, anti-corrosion/anti-freeze coolant (refer to manual for specific mixture)
Common Wear Items:
Clutch plates, brake pads, fork seals, piston rings, air filter, spark plug
Carburetor Tuning:
Can require periodic adjustment based on altitude, temperature, and riding conditions
Proactive Maintenance:
Emphasizes following periodic maintenance schedules to maximize satisfaction and best results.
Importance Of Tools:
Stresses using correct special service tools or equipment to avoid adverse effects on safe operation.
Record Keeping:
Recommends keeping complete records of all maintenance and repairs.
