Category:
Motocross / Off-Road Motorcycle
Target Audience:
Motocross enthusiasts, mechanics, DIY repair individuals.
Competitors 2004:
Yamaha YZ100 (though often 125cc dominated this class), Suzuki RM100, Honda CR100R (less common).
Vehicle Focus:
Performance-oriented small-bore motocrosser, known for its lightweight chassis and potent two-stroke engine.
Manual Value Proposition:
Provides in-depth factory information essential for maintaining peak performance and executing reliable repairs on the KX100.
Scope:
Comprehensive repair, adjustment, installation, removal, disassembly, assembly, and check procedures.
Type:
Factory Service Repair Manual
Format:
Likely PDF (digital) or Printed
Engine:
Top end (cylinder, piston, rings), bottom end (crankshaft, connecting rod, bearings), cooling system, lubrication system, fuel system (carburetor tuning and overhaul), ignition system, exhaust system.
Transmission:
Gearbox disassembly, assembly, inspection, clutch operation and service, shift mechanism.
Chassis:
Frame, suspension (front forks, rear shock absorber), steering system, wheels, hubs, spokes, brakes (front and rear), controls (throttle, clutch, shifter).
Electrical:
Ignition system components, wiring diagrams, lighting, horn, battery, troubleshooting electrical faults.
Maintenance:
Routine checks, cleaning procedures, lubrication points, filter replacements, spark plug service.
Repair:
Detailed step-by-step repair instructions for all major components and systems.
Troubleshooting:
Diagnostic procedures for common and uncommon problems, fault finding charts.
Depth:
Factory-level technical data, including torque specifications, clearances, tolerances, and detailed diagrams for complete overhauls and rebuilds.
Digital Format Details:
Searchable text, high-resolution diagrams, printable pages.
Print Quality Description:
Sharp text and clear, detailed illustrations and photographs.
Binding Description:
If printed, likely professionally bound for durability in a workshop environment.
Paper Quality:
If printed, durable, possibly glossy paper to withstand workshop conditions.
Type:
Liquid-cooled, 2-stroke, single-cylinder
Bore X Stroke:
52.0 mm x 45.8 mm
Compression Ratio:
9.7:1 (typical for the era)
Valve Mechanism:
Reed valve induction
Horsepower Estimate:
Approx. 26-30 hp (at crankshaft, estimated for class)
Torque Estimate:
Approx. 15-17 lb-ft (at crankshaft, estimated for class)
Carburetor Model:
Keihin PWK35 (typical for the era)
Fuel Type:
Unleaded gasoline with 2-stroke oil mix (e.g., 32:1 or 40:1 ratio)
Oil Type:
High-quality 2-stroke motorcycle oil
Fuel Tank Capacity:
Approx. 7.0 Liters (1.8 US gallons)
Type:
6-speed constant mesh
Gear Ratios:
Specific ratios detailed in the manual (e.g., 1st gear: 2.833, 2nd: 2.063, 3rd: 1.579, 4th: 1.294, 5th: 1.130, 6th: 1.000)
Transmission Oil Type:
API GL-4 SAE 80W-90 hypoid gear oil (or equivalent)
Transmission Oil Capacity:
Approx. 0.7 Liters (0.74 US quarts)
Length:
Approx. 1915 mm (75.4 in)
Width:
Approx. 790 mm (31.1 in)
Height:
Approx. 1165 mm (45.9 in)
Wheelbase:
Approx. 1340 mm (52.8 in)
Ground Clearance:
Approx. 325 mm (12.8 in)
Seat Height:
Approx. 875 mm (34.4 in)
Dry Weight:
Approx. 77 kg (169.8 lbs)
Curb Weight:
Not typically specified for motocross bikes, but would include fluids.
Safety Certification:
N/A (Off-road competition vehicle, not street-legal)
Braking System:
Hydraulic disc brakes front and rear.
Suspension Features:
Inverted telescopic front forks with adjustable compression and rebound damping; Uni-Trak rear suspension with adjustable preload, compression, and rebound damping.
Frame Construction:
High-tensile steel semi-double cradle frame for rigidity and impact absorption.
Oil Change Transmission:
Every 10-15 hours of riding or annually.
Air Filter Cleaning:
Every 5-10 hours of riding, depending on conditions.
Spark Plug Inspection:
Every 10-15 hours of riding.
Top End Rebuild:
Recommended every 20-30 hours of hard riding for optimal performance.
Engine Oil:
Specific 2-stroke premix oil recommended by Kawasaki, such as Kixx or equivalent performance 2T oil.
Coolant:
Permanent type anti-freeze coolant (ethylene glycol based) mixed with distilled water (50/50 ratio recommended).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
Piston rings, clutch plates, chain and sprockets, brake pads, fork seals.
Carburetor Tuning:
Sensitivity to altitude and temperature changes; requires proper jetting for optimal performance.
Suspension Maintenance:
Regular fork oil changes and seal inspections are crucial for consistent performance.
Kawasaki Motocross Legacy:
Kawasaki has a long and successful history in motocross, with iconic models like the KX series consistently competing at the highest levels.
Kx100 Development:
The KX100 is a part of Kawasaki's lineage of small-displacement two-stroke motocross bikes, evolving from earlier models with advancements in suspension, engine technology, and chassis design to remain competitive.
Production Era:
The KX100 has been produced in various iterations since the early 1990s, with the 2004 model representing a specific generation of this platform.
