This manual covers the KX100, a competition motocross motorcycle produced from 2001 to 2010. Engineered for youth motocross racers and off-road enthusiasts, the KX100 is renowned for its performance, lightweight chassis, and responsive power delivery. It features a 99cc, 2-stroke, single-cylinder, liquid-cooled engine with Integrated Power Valve System (KIPS), delivering approximately 25-28 horsepower. The motorcycle is built on a high-tensile steel perimeter frame for rigidity and incorporates powerful hydraulic disc brakes at both the front and rear. Its design prioritizes agility and rider control, making it a competitive machine in its class, with a history of success in amateur and professional racing. This comprehensive workshop service manual provides detailed instructions for the maintenance, repair, and troubleshooting of the KX100 (2001-2010). It covers all major systems, including the engine (top-end, bottom-end, cooling, lubrication, carburetion, exhaust), transmission (gearbox, clutch), chassis (frame, suspension, steering, wheels, brakes), and electrical systems. Included are routine maintenance procedures, in-depth repair procedures for engine and component overhauls, diagnostic charts for common issues, and specific technical data such as torque specifications. This manual is an essential resource for professional technicians and DIY enthusiasts aiming to maintain the optimal performance and longevity of their KX100. 🏷️ Basic Information Identification Make: Kawasaki Model: KX100 Model Year Range: 2001-2010 Codes Engine Code General: 2-stroke, single-cylinder, liquid-cooled 👋 Introduction Market Position Motorcycle Segment: Competition Motocross / Off-Road Competitive Analysis Key Competitors Era: Yamaha YZ85, Suzuki RM85, Honda CR85R. Key Features Target Rider: Youth motocross racers and off-road enthusiasts seeking a competitive 85cc class machine. Engineering Focus: Performance, lightweight chassis, responsive power delivery, durability. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service, repair, and maintenance for Kawasaki KX100 motorcycles, model years 2001 through 2010. Page Count Estimated Page Count: ~300-400 (typical for comprehensive workshop manuals) Manual Type Manual Classification: Workshop Service Manual / Repair Manual Intended User: Professional Technicians and DIY Enthusiasts Language Language: English Format Delivery Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain Systems: Engine (top-end, bottom-end, cooling, lubrication), Carburetion, Exhaust, Transmission (gearbox, clutch, shifting mechanism), Fuel Delivery. Chassis Systems: Frame, Suspension (forks, rear shock absorber, linkages), Steering, Wheels, Tires, Brakes (front and rear hydraulic discs), Swingarm. Electrical Systems: Ignition System, Lighting (if applicable), CDI Unit, Wiring Harness, Troubleshooting diagrams. Frame And Bodywork: Frame components, sub-frame, fuel tank, seat, fenders, plastics, decals. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug inspection/replacement, air filter cleaning/replacement, chain adjustment/lubrication, brake pad inspection/replacement, coolant checks. Repair Procedures: Engine disassembly and reassembly (cylinder, piston, crankshaft, transmission components), Clutch overhaul, Carburetor tuning and rebuilding, Suspension fork seal replacement, Brake caliper servicing, Wheel bearing replacement. Troubleshooting: Diagnostic procedures for common issues, electrical fault finding, engine performance problems, starting difficulties. Special Tools Required: Detailed listing and description of essential special tools needed for specific repair procedures. Technical Depth Diagnostic Level: Detailed diagnostic charts and procedures for identifying and resolving mechanical and electrical faults. Rebuild Scope: Complete engine and transmission rebuild procedures, including torque specifications, clearances, and component tolerances. Torque Specifications: Comprehensive torque values for all critical fasteners across all systems. 📊 Manual Specifications File Format PDF Searchability: Searchable text content for easy information retrieval. PDF Compatibility: Compatible with all standard PDF readers. Print Quality Image Resolution: High-resolution diagrams, illustrations, and photographs for clarity. Binding Type Digital Binding: N/A (Digital PDF format) Paper Type Digital Paper Emulation: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke, Single-Cylinder Displacement: 99 cc Bore X Stroke: 52.0 mm x 45.8 mm Cooling System: Liquid-Cooled Reed Valve System: Kawasaki Integrated Power Valve System (KIPS) Compression Ratio: Approx. 10.7:1 (typical for this era) Ignition Timing: Refer to manual for specific ignition timing settings and adjustments. Performance Horsepower Approximate: ~25-28 HP (at rear wheel, estimated) Torque Approximate: ~12-14 lb-ft (at rear wheel, estimated) Fuel System Carburetor Type: Keihin PWK33 Fuel Type: Unleaded gasoline (91 octane or higher recommended) Fuel Mixture: Pre-mix (50:1 ratio of gasoline to 2-stroke oil recommended) Lubrication Crankcase Lubrication: 2-stroke oil mixed with fuel. 🔧 Transmission Standard Transmission Type: 6-Speed Constant Mesh, Return Shift Clutch Type: Wet, Multi-plate Features Gear Ratios Primary Drive: 2.000 (30/15) Gear Ratios Final Drive: 3.333 (50/15) Transmission Fluid Type: SAE 80 hypoid gear oil or equivalent API GL-4 transmission oil. 📐 Dimensions Exterior Overall Length: Approx. 1830 mm (72.0 in) Overall Width: Approx. 760 mm (29.9 in) Overall Height: Approx. 1130 mm (44.5 in) Wheelbase: Approx. 1275 mm (50.2 in) Ground Clearance: Approx. 300 mm (11.8 in) Seat Height: Approx. 870 mm (34.3 in) Weights Dry Weight: Approx. 73 kg (161 lbs) Curb Weight: Not officially specified, but higher than dry weight. Cargo Cargo Capacity: N/A (Competition Dirt Bike) 🛡️ Safety Features Ratings Safety Certification: N/A (Off-road competition vehicle) Active Features Braking System Front: Hydraulic disc brake with petal-type rotor. Braking System Rear: Hydraulic disc brake with petal-type rotor. Passive Features...