Market Position:
The Kawasaki KX80-M2 was a highly competitive entry-level motocross bike in the late 1980s, aimed at junior riders and aspiring racers. It was known for its potent engine and capable chassis within its class.
Competitive Analysis:
Competed against models such as the Suzuki RM80, Honda CR80R, and Yamaha YZ80, offering a distinct riding experience and technical characteristics. This manual provides the essential information to keep these bikes performing optimally.
Key Features:
The manual is presented as a comprehensive, easy-to-understand resource with detailed procedures, clear illustrations, and essential technical data, making it suitable for both professional mechanics and DIY enthusiasts.
Accessibility:
Instant download ensures immediate access to critical repair information, saving time and eliminating shipping delays. Available 24/7 upon purchase.
Systems Covered:
Engine (Top End, Bottom End, Lubrication), Fuel System (Carburetion, Fuel Tank, Fuel Lines), Ignition System, Cooling System, Transmission (Clutch, Gearbox), Drivetrain (Chain, Sprockets), Suspension (Front Forks, Rear Shock Absorber), Brakes (Front and Rear Drum/Disc), Wheels and Tires, Frame and Bodywork, Electrical System (Wiring Harness, Lighting), Controls, Chassis Components.
Electrical System Details:
Includes wiring diagrams, component testing procedures for the ignition system (CDI, coil, spark plug), lighting circuits, and kill switch operation.
Chassis And Frame:
Covers inspection, maintenance, and repair of the frame, subframe, steering head bearings, and swingarm pivot.
Procedures Included:
Routine Maintenance, Adjustments (Carburetor, Clutch, Brakes, Suspension), Troubleshooting, Diagnostics, Removal and Installation of Components, Disassembly and Assembly (Engine, Transmission, Suspension), Component Overhaul, Specifications and Data (Torque Values, Clearances, Fluid Types), Special Tool Usage, Diagrams and Illustrations.
Diagnostic Procedures:
Detailed troubleshooting guides for common starting problems, engine performance issues, electrical faults, and transmission problems are included.
Repair Procedures:
Exhaustive step-by-step instructions for component repair, including engine rebuilds, transmission overhaul, suspension servicing, and brake system repairs.
Adjustment Procedures:
Precise instructions for adjusting carburetor idle speed, jetting, throttle cable, clutch engagement, brake lever free play, and suspension preload.
Wheel And Tire Service:
Includes procedures for wheel bearing maintenance, spoke tensioning, tire mounting and balancing, and recommended tire pressures.
Technical Depth:
Comprehensive, step-by-step procedures for both minor adjustments and major overhauls. Includes detailed explanations, pictorial diagrams, exploded views, and technical specifications crucial for accurate repairs.
Special Tools:
Identification and usage instructions for specific Kawasaki special service tools required for certain repair and adjustment procedures are provided.
Measurements And Tolerances:
Precise measurements and allowable wear limits for critical engine and chassis components are listed, ensuring repairs are performed to factory specifications.
Pictorial Diagrams:
Abundant step-by-step illustrations, exploded diagrams, and photographs to visually guide the user through complex procedures.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Bore X Stroke:
48.0 x 44.0 mm
Cooling System:
Liquid-cooled
Horsepower Est:
Approx. 15-18 HP (This is an estimated range for the class, specific dyno data not provided in manual description)
Torque Specifications:
The manual includes detailed torque specifications for all critical fasteners, essential for proper engine assembly and longevity.
Carburetor:
Mikuni VM24SS (Specifics on jetting and adjustments detailed in manual)
Fuel Type:
Unleaded gasoline with 2-stroke oil pre-mix
Fuel Tank Capacity:
Refer to manual for exact fuel tank capacity.
Ignition Type:
CDI (Capacitor Discharge Ignition)
Safety Ratings:
As a motocross-specific vehicle, formal road safety ratings are not applicable. The manual emphasizes safe operating procedures and correct maintenance to ensure rider safety.
Active Features:
Brake systems (front disc, rear drum), capable suspension, and chassis stability contribute to active safety. Manual details adjustments for optimal performance.
Passive Features:
Durable frame construction, rider ergonomics, and component integrity are key passive safety elements. The manual guides proper assembly and maintenance.
Service Intervals:
The manual contains a detailed periodic maintenance chart, outlining recommended intervals for tasks such as air filter cleaning/replacement, spark plug inspection/replacement, chain lubrication, brake checks, and more. Specific intervals are provided for various operating conditions.
Engine Top End Service:
The manual provides guidance on recommended intervals for top-end rebuilds (piston, rings, cylinder) based on usage, crucial for maintaining peak performance.
Engine Oil Type:
2-stroke engine oil specifically formulated for air- or liquid-cooled engines (e.g., API TC, JASO FD rated). Pre-mix ratio details provided.
Coolant Type:
Permanent antifreeze coolant (ethylene glycol-based) suitable for aluminum engines.
Transmission Oil Type:
Refer to manual for specific SAE viscosity grade (e.g., SAE 80 or SAE 10W-30 gear oil) and capacity.
Clutch Fluid Type:
N/A (Mechanical clutch actuation, does not use hydraulic fluid).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid for the front disc brake system (if equipped). Rear brake is typically drum with grease lubrication.
Common Issues:
Overheating due to improper coolant levels or radiator blockage, carburetor tuning issues, worn clutch components, suspension seal leaks, and general wear and tear on a competition machine. The manual provides solutions for these and other potential problems.
Brand Heritage:
Kawasaki has a long and successful history in motocross racing, with the KX line being a cornerstone of their performance off-road offerings for decades.
Model Evolution:
The KX80 was a consistently developed model within Kawasaki's junior motocross lineup, evolving through various iterations to improve performance and handling. The M2 designation represents a specific model year within the first generation.
Key Changes For 1989:
While specific year-to-year changes require deep historical research, the M2 designation implies specific updates or revisions from previous models, covered in detail within the manual.
Production Years:
The KX80 line, including the M2 variant, was produced through the 1980s and into the early 1990s.
