Target Audience:
DIY mechanics and professional technicians working on Kawasaki KX60-B16 2000 models.
Purpose:
To provide detailed, step-by-step instructions for accurate and efficient repairs and maintenance, ensuring optimal performance and longevity of the vehicle.
Detail Level:
Extremely detailed, comprehensive, step-by-step procedures with pictorial diagrams, exploded views, and photos.
Usability:
Designed for ease of understanding, making complex procedures accessible to less experienced personnel.
Completeness:
100% complete and intact, ensuring no missing or corrupt pages/sections.
Safety Emphasis:
Highlights special notes, precautions, DANGER, CAUTION, and WARNING statements for safe operation and service.
General Coverage:
Comprehensive repair and maintenance for the Kawasaki KX60-B16 2000 model.
Specific Systems:
Engine, chassis, suspension, brakes, electrical system, fuel system, cooling system, lubrication system, exhaust system, transmission, drivetrain, wheels and tires, bodywork.
Type:
Workshop Service Manual
Purpose:
Repair, maintenance, adjustments, troubleshooting.
Delivery Method:
Instant Download
Engine:
Detailed disassembly, assembly, inspection, adjustment, and repair of all engine components including the cylinder, piston, crankshaft, connecting rod, and valve train (if applicable).
Fuel System:
Carburetor adjustment, cleaning, overhaul, fuel tank and lines maintenance.
Ignition System:
Spark plug, ignition coil, and related component testing and adjustment.
Cooling System:
Radiator, water pump, and coolant circuit inspection and maintenance (if applicable).
Lubrication System:
Oil pump, oil filter, and lubrication circuit maintenance.
Transmission:
Gearbox disassembly, assembly, inspection, and adjustment. Clutch operation and maintenance.
Suspension:
Front fork and rear shock absorber maintenance, service, and adjustment. Bushing and seal replacement.
Brakes:
Brake caliper, master cylinder, brake lines, brake pads, and brake shoe inspection, service, and adjustment. Drum and disc brake procedures.
Electrical System:
Wiring diagrams, component testing, battery maintenance, lighting system, and charging system diagnostics.
Chassis And Frame:
Frame inspection, tightening of fasteners, and basic chassis component service.
Wheels And Tires:
Tire pressure checks, wheel bearing service, and spoke tension adjustment.
Maintenance:
Routine maintenance tasks, periodic service, fluid changes, filter replacements.
Troubleshooting:
Diagnostic procedures for common problems, fault finding charts, and symptom-based solutions.
Repair:
Step-by-step instructions for component repair, including disassembly, reassembly, and part replacement.
Adjustment:
Carburetor, clutch, brakes, suspension, and other adjustable components.
Installation Removal:
Procedures for removing and installing major components and sub-assemblies.
Technical Specifications:
Torque values, wear limits, clearances, fluid capacities, and other critical data.
Depth:
Comprehensive, covering basic maintenance to in-depth engine and transmission rebuilds. Includes detailed explanations and pictorial diagrams.
Engine Type:
2-stroke, single-cylinder, liquid-cooled (typically, though specific cooling may vary by sub-variant, but generally KX60s were air-cooled)
Displacement:
59 cc (Cubic Centimeters) - Standard for KX60 models.
Bore X Stroke:
Typically 43.0 x 41.5 mm for KX60 models.
Compression Ratio:
Typically around 7.5:1 for KX60 models.
Horsepower:
Approximately 8.0 - 8.5 HP at ~7500 RPM (typical for this class and era).
Torque:
Approximate torque figures are not always prominently featured for this class, but it would be in the range of 7-8 Nm.
Fuel Delivery:
Carburetor (e.g., Mikuni VM series, typically VM15SC or similar).
Fuel Type:
Unleaded gasoline with 2-stroke oil pre-mix.
Ignition:
CDI (Capacitor Discharge Ignition).
Overall Length:
Refer to manual for precise dimensions, but typically around 1550-1600 mm.
Overall Width:
Refer to manual for precise dimensions, but typically around 720-750 mm.
Overall Height:
Refer to manual for precise dimensions, but typically around 950-1000 mm.
Dry Weight:
Approximately 65-68 kg (crucial for maneuverability).
Curb Weight:
Not typically published for this type of vehicle, but would include fluids.
Oil Change Frequency:
Refer to manual for specific pre-mix ratio and recommendations. Gearbox oil change intervals are critical.
Air Filter Cleaning:
Frequent cleaning is essential for optimal engine performance, especially in dusty conditions.
Spark Plug Inspection:
Regular inspection and cleaning/replacement are vital for proper combustion.
Gearbox Oil:
Refer to manual for specific API GL-4 or GL-5 transmission oil type and viscosity grade (e.g., SAE 10W-30 or 10W-40).
Coolant:
If liquid-cooled, specify the type of antifreeze/coolant required (e.g., ethylene glycol-based).
Brake Fluid:
DOT 3 or DOT 4 brake fluid (check manual for specific recommendation).
2 Stroke Oil:
High-quality 2-stroke pre-mix oil, often JASO FD or API TC rated.
Carburetor Fouling:
Common in 2-strokes due to fuel/oil mixture, requiring regular cleaning and jetting checks.
Clutch Wear:
Wear on clutch plates can occur with aggressive riding, requiring adjustment or replacement.
Suspension Seals:
Fork seals and shock seals can degrade over time, leading to oil leaks.
Air Filter Maintenance:
Crucial for preventing engine wear; neglect can lead to premature rebuilds.
Periodic Maintenance Chart:
The manual contains a detailed periodic maintenance chart to ensure proactive care.
Kawasaki Motorsports:
Kawasaki has a long and successful history in motocross and off-road racing, known for producing competitive and reliable machines.
Kx Series Legacy:
The KX60 was a popular entry-level motocross bike for junior riders, building on Kawasaki's expertise in the KX line.
Kx60 Purpose:
Designed to introduce young riders to the sport of motocross, offering manageable power and forgiving handling.
Production Era:
The KX60 model line generally ran from the mid-1980s through the early 2000s, with the KX60-B16 representing a specific iteration.
