The Kawasaki KX100, produced from 2001 to 2010, is a competition motocross bike engineered for performance-oriented riders in the 100cc class. It is recognized for its aggressive powerband and agile handling, making it a formidable machine on the track. Built with extensive heritage in off-road racing, the KX100 features a robust two-stroke, single-cylinder, liquid-cooled engine with a displacement of 99 cc, known for delivering exciting performance. Its chassis is constructed from high-tensile steel for strength and rigidity, complemented by hydraulic disc brakes front and rear for reliable stopping power. This Service Repair Manual provides comprehensive guidance for the KX100 models spanning 2001 through 2010. It covers all essential aspects of maintenance and repair, including detailed procedures for engine service, such as complete overhauls and top-end rebuilds, as well as carburetor tuning and cooling system maintenance. The manual also delves into chassis service, including suspension, steering, wheels, and brakes, alongside in-depth coverage of the electrical system and troubleshooting common issues. Its purpose is to empower owners and technicians with the knowledge necessary to maintain the vehicle's peak performance and ensure its longevity. 🏷️ Basic Information Identification Make: Kawasaki Model: KX100 Years Covered: 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Codes Product Name: Kawasaki KX100 2001-2010 Service Repair Manual 👋 Introduction Market Position Category: Competition Motocross / Dirt Bike Competitive Analysis Competitors: Yamaha YZ100, Suzuki RM100, Honda CR100 (models within similar displacement and competition class). Key Features Model Focus: Designed for performance-oriented riders in the 100cc motocross class, known for its aggressive powerband and agile handling. Value Proposition Manual Benefit: Empowers owners and technicians with the knowledge to perform all necessary maintenance and repairs, maximizing performance and longevity. 📋 Manual Details Coverage Areas Engine Service: Complete overhaul, top-end rebuild, bottom-end service, carburetor tuning, cooling system service. Chassis Service: Suspension (forks, shock), steering system, wheel and tire maintenance, brake system service (front and rear). Electrical System: Ignition system, lighting, wiring diagrams, troubleshooting electrical faults. Troubleshooting: Diagnostic charts, common problems and solutions, fault finding procedures. Page Count Estimated Pages: 300-500 Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Two-stroke single-cylinder engine maintenance, disassembly, assembly, lubrication, cooling system. Fuel System: Carburetor (Keihin PWK series) tuning, jetting, cleaning, and rebuilding; fuel tank and lines. Transmission Drivetrain: Clutch operation and adjustment, gearbox disassembly and assembly, chain and sprocket maintenance. Suspension System: Front fork servicing (oil changes, seal replacement), rear shock absorber maintenance and adjustment. Brake System: Hydraulic front and rear disc brake system service, pad replacement, caliper maintenance, bleeding procedures. Electrical System: Ignition system components (spark plug, coil), lighting circuits, battery maintenance, wiring diagrams for troubleshooting. Frame Bodywork: Frame inspection, body panel removal and installation, seat, handlebars, and footpeg maintenance. Procedures Included Routine Maintenance: Oil changes, filter cleaning/replacement, chain lubrication and adjustment, spark plug replacement, air filter cleaning. Engine Repair: Top-end rebuild (piston, rings, cylinder, head), crankshaft and connecting rod service, engine bearing replacement. Carburetor Overhaul: Detailed step-by-step instructions for carburetor disassembly, cleaning, inspection, and reassembly. Suspension Rebuild: Front fork seal and bushing replacement, fork oil level and type specifications, rear shock absorber servicing. Brake Bleeding: Proper procedures for flushing and bleeding the hydraulic brake system. Troubleshooting Guides: Systematic approaches to diagnose and resolve common performance issues, starting problems, and electrical faults. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and chassis rebuilds. 📊 Manual Specifications File Format Format: PDF Print Quality Resolution: High-resolution, ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Two-stroke, single-cylinder, liquid-cooled Displacement: 99 cc (6.0 cu in) Bore X Stroke: 52.5 x 45.8 mm (2.07 x 1.80 in) Compression Ratio: 9.7:1 (typical, may vary slightly by year) Valves Timing: Kawasaki Integrated Power-valve System (KIPS) - details covered in manual. Performance Horsepower: Approx. 28-30 hp (at crankshaft, specific figures vary by year and dyno testing) Torque: Approx. 15-16 lb-ft (at crankshaft, specific figures vary) Fuel System Carburetor Model: Keihin PWK35 (typically, specific jetting detailed in manual) Fuel Type: Unleaded gasoline (91 octane or higher recommended) Lubrication Oil Type: 2-stroke engine oil (e.g., Kawasaki KPS 2-Stroke Oil, Yamalube 2R, Motul 800 2T) Fuel Oil Ratio: 50:1 (standard pre-mix, refer to manual for specific recommendations and break-in procedures) 🔧 Transmission Standard Type: 6-speed constant mesh Clutch: Wet, multi-disc Features Gear Ratios: Specific gear ratios are detailed within the manual for accurate maintenance and troubleshooting. Final Drive: O-ring sealed chain (520 pitch, specific count/length covered in manual). Transmission Oil: Manual specifies Kawasaki Genuine Gear Oil API GL-4 SAE 80W or equivalent. 📐 Dimensions Exterior Length: Approx. 76.4 inches (1940 mm) Width: Approx. 31.5 inches (800 mm) Height: Approx. 47.2 inches (1200 mm) Weights Dry Weight: Approx. 163 lbs (74 kg) Curb Weight:...