This manual covers the KX100, a potent two-stroke, single-cylinder competition motorcycle produced between 2001 and 2010. Renowned for its strong performance in the junior motocross category, the KX100 features a liquid-cooled 99cc engine, a 6-speed transmission, and a lightweight frame designed for agility and control. Its long-travel suspension and hydraulic disc brakes are optimized for aggressive off-road riding and racing, making it a competitive choice for amateur and semi-professional riders. The legacy in motocross is evident in the KX100's development, which consistently focused on delivering a powerful engine and a capable chassis. This Workshop Service Manual (WSM) provides comprehensive guidance for the maintenance, repair, and troubleshooting of the KX100 models from 2001 to 2010. It details procedures for all major systems, including the engine, transmission, chassis, brakes, and electrical components. Owners, mechanics, and technicians will find step-by-step instructions for disassembly, reassembly, adjustments, and rebuilds, alongside crucial technical specifications, wiring diagrams, and diagnostic flowcharts. The manual is designed to ensure the optimal performance, reliability, and longevity of the vehicle through proper care and servicing. 🏷️ Basic Information Identification Make: Kawasaki Model: KX100 Model Year Range Covered: 2001-2010 Codes Product Name: Kawasaki KX100 2001-2010 WSM Service Manual Repair 👋 Introduction Market Position Vehicle Class: Motocross/Off-Road Competition Motorcycle Target Audience: Amateur and semi-professional motocross racers, off-road enthusiasts. Competitive Analysis Key Competitors: Honda CR85/CR80, Yamaha YZ100/YZ85, Suzuki RM100/RM85, KTM 105 SX/85 SX. Key Features Engine Type: Two-stroke, single-cylinder, liquid-cooled (typically, though some earlier models might have been air-cooled depending on region/specifics). Suspension Travel: Long-travel front and rear suspension designed for aggressive off-road riding. Frame Construction: Lightweight, high-tensile steel or aluminum perimeter frame for rigidity and handling. Off Road Focus: Optimized for racing and off-road trail riding, featuring knobby tires, high ground clearance, and durable components. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual (WSM) Language: English Format: Digital (likely PDF, searchable) Page Count Estimated Page Count: 300-500 pages (typical for WSMs of this era) 📖 Manual Coverage Systems Covered Engine System: Complete engine overhaul, diagnosis, tuning, lubrication, cooling (if applicable, though usually air-cooled), fuel delivery, ignition system. Transmission System: Clutch operation, gearbox disassembly and reassembly, shift mechanism, lubrication. Chassis System: Frame inspection and repair, suspension (front fork, rear shock absorber) maintenance and adjustments, steering system service. Brake System: Front and rear brake systems (likely disc brakes), caliper service, fluid replacement, bleeding procedures. Electrical System: Wiring diagrams, ignition system components (CDI, spark plug), lighting system, battery maintenance, troubleshooting electrical faults. Fuel System: Carburetor identification, disassembly, cleaning, adjustment (jetting), fuel tank and petcock service. Exhaust System: Exhaust pipe and silencer inspection, maintenance, and potential replacement guidance. Cooling System: Primarily air-cooled, but may cover radiator if liquid-cooled variants exist or for specific model years. Bodywork And Trim: Fairing removal and installation, seat, fenders, plastics, graphics. Procedures Included Maintenance Procedures: Regular service checks, oil changes, filter replacements, chain adjustment, spark plug replacement, brake pad replacement, coolant flush (if applicable). Troubleshooting Guides: Diagnostic flowcharts and symptom-based troubleshooting for common issues across all major systems. Repair Procedures: Step-by-step disassembly and reassembly instructions for major components and sub-assemblies. Rebuild Instructions: Detailed procedures for rebuilding the engine, carburetor, suspension components, and brake calipers. Adjustment Procedures: Carburetor tuning, ignition timing, suspension sag, chain tension, clutch and brake lever free play. Wiring Diagrams: Comprehensive electrical schematics for easy fault diagnosis. Technical Depth Diagnostics: Advanced diagnostic procedures, including electrical testing, compression testing, and carburetor performance analysis. Performance Tuning: Information on optimizing engine performance through carburetor jetting, exhaust modifications, and ignition timing adjustments. Specification Data: Torque specifications, clearances, fluid capacities, and electrical resistance values for all components. 📊 Manual Specifications File Format File Type: Likely PDF Searchability: Typically searchable text-based PDF for efficient information retrieval. Print Quality Image Clarity: High-resolution diagrams, illustrations, and photographs for clarity. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder Displacement: 99cc Bore X Stroke: 52.5 mm x 45.8 mm Cooling System: Liquid-cooled Reed Valve System: Yes, typically KIPS (Kawasaki Integrated Power-valve System) or similar design for optimized powerband. Starting System: Kickstart Performance Horsepower Peak: Approximately 25-30 HP (varied by tuning and year) Torque Peak: Approximately 14-16 lb-ft (varied by tuning and year) Fuel System Carburetor Model: Keihin PWK35 (typical for this model/era) Fuel Type: Unleaded gasoline, 91 octane or higher recommended. Premix Ratio: 50:1 with a high-quality two-stroke oil. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet, multi-plate Features Gear Ratios: Specific gear ratios provided in the manual for each gear. Final Drive: Chain drive Transmission Oil Type: API GL-4, SAE 80W/90 gear oil (typical, consult manual for exact specification). 📐 Dimensions Exterior Overall Length: Approximately 73.2 inches (1860 mm) Overall Width: Approximately 31.7 inches (805 mm) Overall Height: Approximately 44.7 inches (1135 mm) Wheelbase: Approximately 50.6 inches (1285 mm) Ground Clearance:...