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Kawasaki KX85 KX85 II KX100 Complete Workshop Service Repair Manual 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 PDF Download
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Basic Information Identification Make: Kawasaki Model: KX85 Model Variant: KX85 II Model Variant 2: KX100 Product Type: Complete Workshop Service Repair Manual Product Format: PDF Download Generation Covered Years: 2001,...
Type: Motorcycles
Vendor:
Sku: 76805
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| Basic Information | |
| Identification | |
| Make: | Kawasaki |
| Model: | KX85 |
| Model Variant: | KX85 II |
| Model Variant 2: | KX100 |
| Product Type: | Complete Workshop Service Repair Manual |
| Product Format: | PDF Download |
| Generation | |
| Covered Years: | 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013 |
| Introduction | |
| Market Position | |
| Segment: | Competition Motocross Off-Road Motorcycles |
| Competitive Analysis | |
| Competitors: | Yamaha YZ85, Suzuki RM85, Honda CR85R. |
| Key Features | |
| Target Audience: | Junior motocross riders and off-road enthusiasts. |
| Performance Focus: | Lightweight design, potent two-stroke engines, and advanced suspension for competitive racing. |
| Manual Details | |
| Coverage Areas | |
| Primary Coverage: | Comprehensive service, repair, and maintenance for Kawasaki KX85, KX85 II, and KX100 models. |
| Page Count | |
| Estimated Page Count: | Varies by specific model year, typically several hundred pages. |
| Manual Type | |
| Type: | Workshop Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | Digital PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Engine disassembly, assembly, tuning, troubleshooting, top-end, bottom-end, cooling system. |
| Transmission: | Gearbox removal, disassembly, inspection, assembly, clutch operation and adjustment. |
| Chassis And Suspension: | Frame, front fork (USD telescopic), rear shock absorber (Uni-Trak), swingarm, bearings, and linkages. |
| Brakes: | Front and rear brake systems, hydraulic circuits, caliper service, master cylinder overhaul, pad replacement. |
| Electrical System: | Ignition system, lighting, wiring diagrams, battery, CDI unit, troubleshooting electrical faults. |
| Fuel System: | Carburetor disassembly, cleaning, adjustment, fuel tank, fuel lines, and petcock. |
| Exhaust System: | Exhaust pipe and silencer maintenance, removal, and installation. |
| Cooling System: | Radiator, coolant hoses, and flushing procedures. |
| Procedures Included | |
| Maintenance: | Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service. |
| Troubleshooting: | Diagnostic procedures for common problems, fault finding trees. |
| Repair: | Detailed step-by-step repair instructions for all major components. |
| Rebuilds: | Complete engine and transmission rebuild procedures. |
| Assembly Disassembly: | Complete guide to taking apart and reassembling the motorcycle. |
| Technical Depth | |
| Depth: | In-depth technical information suitable for professional mechanics and experienced DIY enthusiasts. |
| Diagnostic Focus: | Extensive diagnostic information for identifying and resolving mechanical and electrical issues. |
| Manual Specifications | |
| File Format | |
| Digital Format: | |
| Print Quality | |
| Clarity And Resolution: | High-resolution scans, ensuring clear text, diagrams, and illustrations. |
| Binding Type | |
| Delivery Method: | Instant PDF download, no physical binding. |
| Paper Type | |
| Digital Storage: | Digital format suitable for viewing on computers, tablets, and smartphones. |
| Searchability | |
| Text Searchable: | Yes, PDF is typically text-searchable for easy information retrieval. |
| Engine Specifications | |
| Primary Engine | |
| Engine Type Kx85 Kx85Ii: | Liquid-cooled, 2-stroke, single-cylinder |
| Engine Type Kx100: | Liquid-cooled, 2-stroke, single-cylinder |
| Bore Stroke Kx85 Kx85Ii: | 48.5 x 45.8 mm |
| Bore Stroke Kx100: | 52.5 x 45.8 mm |
| Displacement Kx85 Kx85Ii: | 84 cc |
| Displacement Kx100: | 99 cc |
| Compression Ratio: | 9.9:1 (typical, may vary slightly by year) |
| Performance | |
| Horsepower Kx85 Kx85Ii: | Approx. 25-27 HP (estimated, varies by year/tuning) |
| Horsepower Kx100: | Approx. 28-30 HP (estimated, varies by year/tuning) |
| Torque: | Not typically published as a primary spec for this class, but substantial for its size. |
| Fuel System | |
| Carburetor Kx85 Kx85Ii: | Keihin PWK28 |
| Carburetor Kx100: | Keihin PWK30 |
| Fuel Type: | Unleaded gasoline (minimum 91 octane recommended for optimal performance) |
| Fuel Mixture: | Pre-mix (2-stroke engine oil mixed with gasoline at a 20:1 or 32:1 ratio as specified in manual). |
| Ignition System: | Digital CDI |
| Transmission | |
| Standard | |
| Type: | 6-speed constant mesh |
| Optional | |
| Variants: | N/A (standardized across models) |
| Features | |
| Clutch: | Wet, multi-disc, cable-operated |
| Final Drive: | Chain |
| Dimensions | |
| Exterior | |
| Length: | Approx. 1845 mm (72.6 in) for KX85/KX85 II, 1920 mm (75.6 in) for KX100 |
| Width: | Approx. 765 mm (30.1 in) |
| Height: | Approx. 1150 mm (45.3 in) |
| Wheelbase: | Approx. 1260 mm (49.6 in) for KX85/KX85 II, 1285 mm (50.6 in) for KX100 |
| Weights | |
| Dry Weight Kx85 Kx85Ii: | Approx. 73 kg (161 lbs) |
| Dry Weight Kx100: | Approx. 75 kg (165 lbs) |
| Fuel Tank Capacity: | 5.0 Liters (1.3 US gal) |
| Seat Height: | Approx. 850 mm (33.5 in) |
| Safety Features | |
| Ratings | |
| Safety Certifications: | Not applicable for competition off-road motorcycles in the same way as street vehicles. |
| Active Features | |
| Braking System: | Hydraulic disc brakes front and rear for strong stopping power. |
| Suspension: | Long-travel adjustable suspension (USD front, Monoshock rear) for stability and control. |
| Passive Features | |
| Frame Design: | Rigid perimeter frame designed for optimal handling and rider feedback. |
| Technology Features | |
| Infotainment | |
| Infotainment System: | N/A (No infotainment features on this competition model). |
| Driver Assistance | |
| Driver Assistance Systems: | N/A (No electronic driver assistance features). |
| Connectivity | |
| Connectivity Features: | N/A (No connectivity features). |
| Engine Management | |
| Engine Management System: | Mechanical carburetor and CDI ignition provide robust, albeit simple, engine control. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Refer to manual for specific hours/miles; typically after every few riding sessions or per manufacturer recommendation. |
| Air Filter Cleaning: | Frequent cleaning or replacement, especially in dusty conditions. |
| Spark Plug Replacement: | Refer to manual; typically based on hours of use or performance issues. |
| Top End Rebuild: | Recommended based on operating hours (e.g., 20-50 hours for racing, longer for recreational use). |
| Fluid Specifications | |
| Engine Oil Type: | High-quality 2-stroke premix oil (e.g., SAE 10W-30 for transmission lubrication, if applicable, but primary is pre-mix). |
| Coolant Type: | Permanent type antifreeze/coolant (50/50 mix with distilled water). |
| Brake Fluid Type: | DOT 3 or DOT 4 hydraulic brake fluid. |
| Known Issues | |
| Common Wear Items: | Clutch plates, piston rings, spark plugs, chain and sprockets, brake pads. |
| Carburetor Tuning: | Can be sensitive to altitude and temperature changes, requiring periodic adjustment. |
| Suspension Seals: | Fork seals and shock seals can be subject to wear with heavy use. |
| Vehicle History | |
| Brand Heritage | |
| Kawasaki Off Road: | Kawasaki has a long and successful history in motocross and off-road racing, consistently producing competitive machinery. |
| Model Evolution | |
| Kx Lineage: | The KX series has been a staple in junior motocross for decades, evolving with chassis and engine technology. |
| Production | |
| Manufacturing Location: | Primarily Japan, with potential assembly in other regions depending on market. |
| Awards & Recognition | |
| Recognitions | |
| Racing Success: | Kawasaki KX models have a history of success in amateur and professional motocross racing worldwide. |
| Ratings | |
| Customer Satisfaction: | Generally high due to performance and durability when properly maintained. |