Applicable Years:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Coverage Areas:
Comprehensive factory service and repair for KX85 and KX100 models
Primary Format:
PDF Download
Secondary Format:
WINRAR Archive
Manual Type:
Factory Service Repair Manual
File Integrity:
Real files, not scans
Search Functionality:
Enabled by the PDF format, allowing users to quickly locate specific terms, part numbers, or procedures.
Delivery Method:
Instant Download
Operating Systems:
Win95/98/ME/XP/vista/7/Linux/MAC
General Information:
Includes overview, specifications, and general maintenance precautions.
Fuel System:
Carburetor tuning, fuel delivery, cleaning, and inspection.
Cooling System:
Radiator, coolant, water pump, and thermostat maintenance and repair.
Engine Top End:
Cylinder head, piston, rings, cylinder, and valve train (if applicable to two-stroke design) disassembly, inspection, and reassembly.
Engine Right Side:
Clutch, ignition system components, and power valve mechanism.
Engine Removal Installation:
Detailed steps for removing and reinstalling the engine from the chassis.
Engine Bottom End Transmission:
Crankcase, crankshaft, connecting rod, bearings, transmission gears, shift mechanism, and seals.
Wheels Tires:
Wheel bearing maintenance, spoke tension adjustment, tire pressure, and replacement.
Final Drive:
Chain and sprocket inspection, lubrication, adjustment, and replacement.
Brakes:
Hydraulic brake system maintenance (fluid replacement, bleeding), caliper, master cylinder, and rotor inspection/replacement.
Suspension:
Front fork (USD forks) and rear shock absorber maintenance, seal replacement, oil levels, and adjustments.
Steering:
Handlebar, steering stem, bearings, and fork triple clamp inspection and adjustment.
Frame:
Chassis inspection for damage, alignment, and component mounting.
Electrical System:
Ignition system, lighting (if applicable), wiring diagrams, and component testing.
Appendix:
Torque specifications, special tools, troubleshooting charts, and wiring diagrams.
Maintenance:
Routine checks, lubrication, filter changes, fluid changes, and adjustments.
Troubleshooting:
Diagnosis of common problems, symptoms, and corrective actions.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly.
Diagnostics:
Procedures for identifying faulty components and systems.
Depth:
Complete factory-level service and repair, covering basic maintenance to full engine rebuilds.
Specific Procedures Highlighted:
Engine disassembly/assembly, clutch service, carburetor rebuild, suspension fork seal replacement, and electrical system troubleshooting.
Engine Type:
2-Stroke, liquid-cooled, single-cylinder
Displacement:
84.7 cc (4.9 cu in)
Bore X Stroke:
48.5 x 45.8 mm
Compression Ratio:
Typically around 8.8:1 (subject to year and specific model variant)
Engine Type:
2-Stroke, liquid-cooled, single-cylinder
Displacement:
99 cc (6.0 cu in)
Bore X Stroke:
52.5 x 45.8 mm
Compression Ratio:
Typically around 8.8:1 (subject to year and specific model variant)
Carburetor Kx85:
Keihin PWK28 (typical, may vary slightly by year)
Carburetor Kx100:
Keihin PWK34 (typical, may vary slightly by year)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Oil Mixing:
2-Stroke oil mixed with fuel at a specified ratio (refer to manual for exact ratio).
Horsepower Kx85:
Approx. 20-25 HP (peak, varies by year and tuning)
Horsepower Kx100:
Approx. 25-30 HP (peak, varies by year and tuning)
Oil Change Interval:
Varies based on riding hours; consult manual for specific recommendations (e.g., after every few races or specific riding hours).
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (typically after every few rides).
Spark Plug Replacement:
Refer to manual for recommended replacement intervals (e.g., 50-100 hours of use).
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio recommended).
Brake Fluid Type:
DOT 3 or DOT 4 (verify exact specification in manual).
Common Wear Items:
Clutch plates, piston rings, spark plugs, brake pads, chain and sprockets, and suspension seals are common wear items on high-performance 2-stroke motocross bikes.
Carburetor Maintenance:
Carburetors may require periodic cleaning and jetting adjustments depending on altitude, temperature, and fuel quality.
Kawasaki Legacy:
Kawasaki has a long and successful history in motocross and off-road racing, with the KX line being a prominent competitor for decades.
Kx85 Kx100 Development:
These models represent Kawasaki's entry-level and intermediate offerings in the 85cc and 100cc motocross classes, designed to develop young riders' skills and provide competitive performance.
Kx85 Changes 2000-2010:
While core design remained consistent, minor updates may have included suspension valving, carburetor jetting, graphics, and chassis refinements over these model years. The manual covers these evolutions.
Manufacturing Location:
Typically manufactured in Japan by Kawasaki Heavy Industries.
