2001-2011 Kawasaki KX85 KX85 II KX100 2-Stroke Motorcycle Repair Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: KX85, KX85 II, KX100 Model Variants Covered: KX85, KX85 II, KX100 Engine Type: 2-Stroke Generation Product Name: 2001-2011 Kawasaki KX85 KX85 II KX100 2-Stroke Motorcycle Repair Manual PDF Download Codes Model Codes Implied: KX85-A1 to KX85-A11, KX85-B1 to KX85-B11, KX100-A1 to KX100-A11 (Internal Kawasaki coding may vary) 👋 Introduction Market Position Product Category: Off-Road Motorcycle (Motocross/Off-Road Competition) Target Audience: Owners, mechanics, and enthusiasts of Kawasaki KX85, KX85 II, and KX100 motorcycles. Competitive Analysis Competitor Models: Yamaha YZ85, Suzuki RM85, KTM 85 SX, Honda CR85R (during the covered model years). Key Features Digital Access: Instant download after payment, accessible on various devices (smartphones, tablets, computers). Environmental Benefit: Reduced paper consumption compared to traditional printed manuals. Durability Feature: Lifetime Protection Policy for lost or damaged downloads. Convenience: Printable pages allow for clean, job-specific use without damaging an original manual. 📋 Manual Details Coverage Areas Model Year Coverage: 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011 Specific Models Covered: Kawasaki KX85, Kawasaki KX85 II, Kawasaki KX100 Page Count Estimated Page Count: Varies by specific model and year, typically 300-500+ pages for comprehensive manuals. Manual Type Manual Type: Repair Manual, Workshop Manual, Service Manual, Owner's Manuals (implied coverage of owner-level topics), Parts Catalogs (implied) Language Language: English Format Format: Electronic Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, inspection, and repair for 2-stroke engines. Fuel System: Carburetor adjustment, cleaning, overhaul, fuel tank, fuel lines. Lubrication And Cooling: Two-stroke oil injection system (if applicable), cooling system maintenance (liquid-cooled models). Transmission Drive: Gearbox inspection, repair, clutch operation, drive chain and sprocket maintenance. Steering Suspension: Handlebar and steering assembly, front forks (suspension, seals, oil), rear shock absorber service. Electrical System: Ignition system, lighting, wiring diagrams, battery maintenance, troubleshooting. Bodywork Frame: Fairings, fenders, seat, frame inspection, body panel removal and installation. Intake Exhaust: Airbox maintenance, reed valve inspection, exhaust system service. Procedures Included Routine Maintenance: Pre-ride checks, oil changes (gearbox), chain lubrication, filter cleaning/replacement. Engine Rebuild: Piston and ring replacement, cylinder honing, crankshaft and bearing service, cylinder head service. Troubleshooting: Advanced troubleshooting guides for common mechanical and electrical issues. Component Removal Installation: Detailed step-by-step instructions for removing and installing all major components. Technical Depth Diagnostic Capabilities: Covers diagnostic procedures for engine performance, electrical faults, and suspension issues. Repair Scope: Comprehensive repair procedures from minor adjustments to complete engine and gearbox overhauls. Parts Information: Implied availability of parts diagrams and identification for ordering. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality Recommendation: High-resolution, suitable for printing individual pages or sections. Searchable text is a key benefit. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type Recommendation: N/A (Digital Download - printable on various paper types) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke, single-cylinder Kx85 Displacement: 84 cc Kx100 Displacement: 99 cc Bore Stroke Kx85: 43.5 x 55.0 mm Bore Stroke Kx100: 52.5 x 45.8 mm Compression Ratio Kx85: 9.1:1 (approx.) Compression Ratio Kx100: 9.7:1 (approx.) Ignition: Digital CDI Performance Horsepower Kx85: Approx. 27-29 hp (at peak RPM, varies by year and specific tune) Horsepower Kx100: Approx. 30-32 hp (at peak RPM, varies by year and specific tune) Fuel System Carburetor Kx85: Keihin PWK35 (or similar specification) Carburetor Kx100: Keihin PWK38 (or similar specification) Fuel Type: Unleaded gasoline with a minimum octane rating of 91 (AKI), mixed with appropriate 2-stroke oil. 2 Stroke Oil Type: High-quality 2-stroke motorcycle oil meeting JASO FD or ISO-L-EGD standards. 🔧 Transmission Standard Transmission Type: 6-speed manual Optional Optional Transmission: N/A (Standard 6-speed) Features Clutch Type: Wet multi-disc Final Drive: Chain Drive 📐 Dimensions Exterior Wheelbase Kx85: Approx. 1260 mm (49.6 in) Wheelbase Kx100: Approx. 1275 mm (50.2 in) Weights Curb Weight Kx85: Approx. 75 kg (165 lbs) Curb Weight Kx100: Approx. 79 kg (174 lbs) 🛡️ Safety Features Ratings Safety Ratings: N/A (Off-road vehicles are not subject to the same automotive safety rating systems). Active Features Brakes Front: Hydraulic disc Brakes Rear: Hydraulic disc Passive Features Handlebars: High-tensile steel handlebars for durability and rider control. 💡 Technology Features Infotainment Infotainment Features: N/A (Basic off-road motorcycle design, no infotainment features). Driver Assistance Driver Assistance Systems: N/A (No electronic rider aids or driver assistance systems). Connectivity Connectivity Options: N/A (No Bluetooth or smartphone integration). 🔧 Maintenance Service Intervals Engine Oil Change: Check and change gearbox oil every 10-15 hours of operation or annually. Consult manual for specific capacity and type. Air Filter Cleaning: Clean air filter after every few rides, or more frequently in dusty conditions. Replace as needed. Spark Plug Service: Inspect and clean or replace spark plug every 15-20 hours of operation. Recommended plug: NGK BR9EG or equivalent. Chain Maintenance: Lubricate drive chain every 5-10 hours of operation. Check and adjust chain tension as needed. Fluid Specifications Gearbox Oil...
Piston and ring replacement, cylinder honing, crankshaft and bearing service, cylinder head service.
Troubleshooting:
Advanced troubleshooting guides for common mechanical and electrical issues.
Component Removal Installation:
Detailed step-by-step instructions for removing and installing all major components.
Technical Depth
Diagnostic Capabilities:
Covers diagnostic procedures for engine performance, electrical faults, and suspension issues.
Repair Scope:
Comprehensive repair procedures from minor adjustments to complete engine and gearbox overhauls.
Parts Information:
Implied availability of parts diagrams and identification for ordering.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality Recommendation:
High-resolution, suitable for printing individual pages or sections. Searchable text is a key benefit.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type Recommendation:
N/A (Digital Download - printable on various paper types)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder
Kx85 Displacement:
84 cc
Kx100 Displacement:
99 cc
Bore Stroke Kx85:
43.5 x 55.0 mm
Bore Stroke Kx100:
52.5 x 45.8 mm
Compression Ratio Kx85:
9.1:1 (approx.)
Compression Ratio Kx100:
9.7:1 (approx.)
Ignition:
Digital CDI
Performance
Horsepower Kx85:
Approx. 27-29 hp (at peak RPM, varies by year and specific tune)
Horsepower Kx100:
Approx. 30-32 hp (at peak RPM, varies by year and specific tune)
Fuel System
Carburetor Kx85:
Keihin PWK35 (or similar specification)
Carburetor Kx100:
Keihin PWK38 (or similar specification)
Fuel Type:
Unleaded gasoline with a minimum octane rating of 91 (AKI), mixed with appropriate 2-stroke oil.
2 Stroke Oil Type:
High-quality 2-stroke motorcycle oil meeting JASO FD or ISO-L-EGD standards.
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Optional
Optional Transmission:
N/A (Standard 6-speed)
Features
Clutch Type:
Wet multi-disc
Final Drive:
Chain Drive
📐 Dimensions
Exterior
Wheelbase Kx85:
Approx. 1260 mm (49.6 in)
Wheelbase Kx100:
Approx. 1275 mm (50.2 in)
Weights
Curb Weight Kx85:
Approx. 75 kg (165 lbs)
Curb Weight Kx100:
Approx. 79 kg (174 lbs)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Off-road vehicles are not subject to the same automotive safety rating systems).
Active Features
Brakes Front:
Hydraulic disc
Brakes Rear:
Hydraulic disc
Passive Features
Handlebars:
High-tensile steel handlebars for durability and rider control.
💡 Technology Features
Infotainment
Infotainment Features:
N/A (Basic off-road motorcycle design, no infotainment features).
Driver Assistance
Driver Assistance Systems:
N/A (No electronic rider aids or driver assistance systems).
Connectivity
Connectivity Options:
N/A (No Bluetooth or smartphone integration).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Check and change gearbox oil every 10-15 hours of operation or annually. Consult manual for specific capacity and type.
Air Filter Cleaning:
Clean air filter after every few rides, or more frequently in dusty conditions. Replace as needed.
Spark Plug Service:
Inspect and clean or replace spark plug every 15-20 hours of operation. Recommended plug: NGK BR9EG or equivalent.
Chain Maintenance:
Lubricate drive chain every 5-10 hours of operation. Check and adjust chain tension as needed.
Fluid Specifications
Gearbox Oil Type:
SAE 10W-40 API SG or higher, or specific Kawasaki motorcycle gear oil. Capacity: ~0.8 liters. Consult manual for exact type and quantity.
Coolant Type:
Permanent type antifreeze coolant (50% solution with distilled water) for liquid-cooled models.
Known Issues
Common Wear Items:
Clutch plates, piston rings, reed valves, wheel bearings, fork seals, and chain/sprockets are common wear items requiring periodic replacement.
Two Stroke Specific Maintenance:
Regular decarbonization of the exhaust port and piston crown is essential for optimal performance.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycle Division:
Kawasaki Heavy Industries has a long and successful history in motorcycle manufacturing, particularly in the off-road and racing segments with the KX line.
Model Evolution
Kx Series Legacy:
The KX85 and KX100 are successors to a long line of successful small-displacement Kawasaki motocross bikes, designed for youth riders and competition.
Production
Production Period:
The KX85 and KX100 have been in continuous production since their introduction, with this manual covering the generation from 2001 to 2011.
🏆 Awards & Recognition
Recognitions
Motocross Reputation:
The Kawasaki KX line has a strong reputation in amateur and professional motocross racing, often lauded for its powerful engines and competitive chassis.
Ratings
Industry Reviews:
While specific awards for these model years might not be readily available, the KX85 and KX100 consistently received positive reviews for their performance and handling in their class.