Target Audience:
DIY mechanics, home mechanics, and professional technicians working on Kawasaki KX85 dirt bikes.
Manual Value Proposition:
Provides factory-level accuracy and detail, essential for proper maintenance and repair, often surpassing aftermarket alternatives.
Factory Origin:
Directly from Kawasaki, ensuring accuracy and completeness of procedures and specifications.
Comprehensiveness:
Covers all aspects of the vehicle, from basic maintenance to complete engine overhauls and electrical troubleshooting.
Ease Of Use:
Designed for clarity with sequential steps and detailed illustrations.
Engine Mechanical:
Engine disassembly, assembly, inspection, overhaul procedures, piston, cylinder, crankshaft, connecting rod, and valve train.
Engine Cooling:
Radiator, hoses, coolant checks, and system bleeding procedures.
Fuel System:
Carburetor removal, disassembly, cleaning, adjustment, fuel tank, fuel lines, and fuel pump (if applicable).
Ignition System:
CDI unit, spark plug, ignition timing checks, and related components.
Transmission Drivetrain:
Clutch operation, gearbox disassembly and assembly, gear inspection, chain and sprocket maintenance.
Chassis Frame:
Frame inspection, sub-frame maintenance, and general chassis integrity checks.
Suspension Front:
Front fork disassembly, assembly, oil change, seal replacement, and adjustment procedures.
Suspension Rear:
Rear shock absorber inspection, linkage lubrication, and swingarm bearing maintenance.
Brakes Front:
Brake lever, caliper, master cylinder, pad replacement, fluid bleeding, and disc inspection.
Brakes Rear:
Brake pedal, caliper, master cylinder, pad replacement, fluid bleeding, and disc inspection.
Wheels Tires:
Wheel bearing inspection, spoke tension adjustment, and tire pressure recommendations.
Electrical System:
Wiring diagrams, lighting, battery maintenance, and basic circuit troubleshooting.
Control Cables:
Throttle cable, clutch cable inspection, adjustment, and replacement.
Exhaust System:
Exhaust pipe and silencer removal, inspection, and reinstallation.
Bodywork:
Fairing, seat, and fender removal and installation.
Routine Maintenance:
Oil changes, filter replacement, chain lubrication and adjustment, spark plug checks.
Troubleshooting:
Diagnostic charts and symptom-based problem-solving guides.
Disassembly Assembly:
Step-by-step instructions for component removal and reinstallation.
Repair Rebuild:
Detailed procedures for overhauling engine, transmission, and suspension components.
Adjustments:
Carburetor tuning, clutch and brake lever adjustments, chain slack settings.
Diagnostic Capability:
Advanced diagnostics for engine performance, electrical faults, and mechanical issues.
Rebuild Scope:
Complete engine and transmission rebuilds, including component tolerance checks and specifications.
Specifications Detail:
Precise torque values, clearances, fluid capacities, and wear limits for all components.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
84 cm³ (5.1 cu in)
Bore X Stroke:
48.5 x 45.8 mm (1.91 x 1.80 in)
Compression Ratio:
9.9:1 (Typically)
Valve System:
Reed valve intake
Carburetor:
Keihin PWK28, single
Horsepower Estimate:
Approx. 21-23 HP (factory figures vary and are often not officially published for competition bikes).
Torque Estimate:
Not officially published, but significant for its class.
Fuel Type:
Unleaded gasoline (minimum 91 octane recommended)
Fuel Mixture:
2-stroke pre-mix oil at 50:1 ratio (Kawasaki K2 or equivalent)
Engine Oil Change:
Refer to manual for specific hours/conditions, typically after intensive use or a set number of riding hours.
Air Filter Cleaning:
Recommended after every few rides or as dictated by dusty conditions.
Chain Lubrication Adjustment:
Regularly, based on riding conditions (every few hours of riding).
Spark Plug Inspection:
Periodically, or as per manual recommendations based on mileage/hours.
Top End Rebuild:
Intervals vary greatly based on usage, but typically between 30-60 hours of hard racing for optimal performance.
Engine Oil Type:
Refer to manual, typically a high-quality 2-stroke pre-mix oil (e.g., Kawasaki K2, Yamalube, Motul).
Transmission Oil Type:
SAE 10W-30 API SE classification or higher (e.g., Kawasaki Gear Oil 10W-30).
Coolant Type:
Permanent type antifreeze coolant, mixed 50% with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Clutch Wear:
Clutch plates can wear with aggressive riding; manual details inspection and replacement.
Suspension Seals:
Fork and shock seals can degrade over time and with hard use; manual provides seal replacement procedures.
Carburetor Jetting:
Carburetor jetting may need adjustment based on altitude, temperature, and modifications; manual covers tuning.
