Market Segment:
Entry-level to intermediate motocross racing and recreational off-road riding.
Competitors:
Yamaha YZ85, Honda CR85R, Suzuki RM85.
Vehicle Purpose:
Designed for competitive junior motocross racing and aggressive off-road riding.
Manual Value Proposition:
Provides essential information for maintaining and repairing the KX85, empowering owners to perform DIY maintenance and diagnostics, thus saving on service costs and maximizing performance.
Manual Title:
Kawasaki KX85 2001-2013 Motorcycle Repair Service Manual
Specific Years Mentioned In Description:
2001, 2002, 2003, 2004, 2005
Estimated Page Count:
Comprehensive (Exact number not provided, typical for this range is 300-500 pages)
Manual Type:
Repair Service Manual
Engine Systems:
Engine disassembly, assembly, lubrication, cooling, fuel system, exhaust system, ignition system, carburetor, engine maintenance, top-end overhaul, bottom-end overhaul.
Transmission Systems:
Clutch operation and service, gearbox inspection and repair, shifting mechanism.
Chassis Systems:
Frame inspection and repair, suspension (front fork and rear shock absorber), steering system, wheel and tire service, brake systems (front and rear).
Electrical Systems:
Ignition system components, wiring diagrams, lighting system, basic electrical troubleshooting.
Maintenance Procedures:
Regular maintenance checks, oil changes, filter replacements, chain adjustment, spark plug service, carburetor cleaning and adjustment.
Repair Procedures:
Component-level repair, engine rebuilding, suspension fork rebuild, brake caliper service, carburetor overhaul, electrical component testing.
Troubleshooting Procedures:
Diagnostic charts for common problems, step-by-step troubleshooting guides for engine, electrical, and mechanical issues.
Technical Depth:
Detailed step-by-step instructions for maintenance, repair, and overhaul. Includes torque specifications, clearances, and diagnostic information for advanced users and mechanics.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Displacement:
84 cc (common for KX85, specific to the model/generation)
Bore X Stroke:
48.5 mm x 45.8 mm (typical for this era KX85)
Compression Ratio:
9.2:1 (approximate, varies by year)
Reed Valve System:
Petal reed valve intake
Horsepower Approximate:
20-25 HP (estimated, peak power varies by year and tune)
Torque Approximate:
11-13 lb-ft (estimated)
Carburetor Type:
Keihin PWK28 (standard, common size for this displacement)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Fuel Mixture:
Pre-mix oil for 2-stroke engine (specific ratio typically 32:1 or 40:1 with quality 2-stroke oil)
Overall Length:
Approx. 1820 mm (71.7 in)
Overall Width:
Approx. 750 mm (29.5 in)
Overall Height:
Approx. 1115 mm (43.9 in)
Wheelbase:
Approx. 1240 mm (48.8 in)
Ground Clearance:
Approx. 305 mm (12.0 in)
Dry Weight:
Approx. 74 kg (163 lbs)
Curb Weight:
Not typically specified for motocross bikes, but generally around 80-85 kg with fluids.
Fuel Tank Capacity:
Approx. 5.0 L (1.3 US gal)
Safety Certifications:
N/A (Off-road competition vehicle, not typically rated by NHTSA/Euro NCAP)
Braking System Front:
Hydraulic disc brake
Braking System Rear:
Hydraulic disc brake
Suspension Front:
Telescopic front fork (e.g., upside-down design common)
Suspension Rear:
Monoshock rear suspension (Uni-Trak system)
Tire Size Front:
70/100-17 (typical for this class)
Tire Size Rear:
90/100-14 (typical for this class)
Infotainment System:
N/A (Pure performance motocross bike, no infotainment features).
Driver Assistance Features:
N/A (No electronic rider aids like ABS or traction control on this model).
Connectivity Features:
N/A.
Power Valve System:
Kawasaki's KIPS (Kawasaki Integrated Power Valve System) for improved low-end torque and broader powerband.
Oil Change Interval:
Every 10-15 hours of riding for transmission oil. Pre-mix oil is added with fuel.
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Spark Plug Replacement:
Every 20-40 hours of riding, or as needed based on inspection.
Top End Rebuild:
50-100 hours (piston, rings) for competitive use, longer for recreational use. Crankshaft bearings and seals at 100-200 hours.
Transmission Oil Capacity:
Approx. 0.68 L (0.72 US qt)
Coolant Type:
Permanent type antifreeze coolant (50/50 mixture with distilled water recommended)
Common Wear Items:
Clutch plates, piston rings, chain and sprockets, wheel bearings, fork seals.
Carburetor Tuning Sensitivity:
2-stroke engines, especially with carburetion, can be sensitive to altitude and temperature changes, requiring occasional re-jetting or adjustment.
Suspension Maintenance:
Fork oil and seal replacement, shock linkage lubrication are critical for optimal performance and longevity.
Example Air Filter Part Number:
Refer to manual for exact OEM part numbers (e.g., 11013-1220).
Example Spark Plug Part Number:
NGK BR9EG (common fitment, verify in manual).
Kawasaki Legacy:
Kawasaki has a long and successful history in motorcycle racing, particularly in motocross and supercross with its KX line.
Kx85 Development:
The KX85 succeeded the highly popular KX80. The 2001-2013 generation saw updates in suspension, chassis rigidity, engine tuning, and styling to remain competitive.
Key Updates 2001-2013:
Typically included revised suspension settings, chassis geometry adjustments, and carburetor tuning for improved power delivery and handling.
Manufacturing Location:
Japan (primary)
Motocross Wins:
The KX85 has been a consistent contender and winner in junior motocross championships worldwide.
Industry Reviews:
Consistently praised by motocross publications for its performance, handling, and competitive edge in its class.
Manual Quality Assurance:
The provided service manual is essential for maintaining the competitive edge and longevity of the KX85.
