This workshop service manual covers the KX60, an off-road motorcycle designed for youth motocross and sport riding, produced between 1998 and 2010. As part of the renowned KX lineage, this entry-level to intermediate dirt bike is celebrated for its ease of handling and the reputation for durable off-road machinery. The KX60 features a 59.6 cc air-cooled, 2-stroke engine, a 6-speed manual transmission, and front and rear disc brakes, making it a capable platform for developing young riders' skills. This comprehensive 250-page English-language manual provides detailed guidance on all aspects of the KX60. It includes step-by-step procedures for routine maintenance, troubleshooting common issues, and complete repairs for all major systems, including the engine, transmission, chassis, suspension, brakes, fuel, and electrical systems. With in-depth explanations, diagrams, and technical specifications, this manual is an essential resource for owners, mechanics, and technicians to ensure the optimal performance, reliability, and longevity of their KX60. 🏷️ Basic Information Identification Make: Kawasaki Model: KX60 Type: Off-road Motorcycle (Dirt Bike) Codes Engine Codes: Likely KSR110 engine family variants (specific codes not provided in source data) 👋 Introduction Market Position Market Segment: Entry-level to intermediate youth motocross/off-road sportbike. Competitive Analysis Competitors: Yamaha YZ80/85, Suzuki RM80/85, Honda CR80/85. Key Features Ease Of Use: Designed for younger riders, emphasizing ease of handling and maintenance. Durability: Kawasaki's reputation for robust off-road machinery. 📋 Manual Details Coverage Areas Years Covered: 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Page Count: 250 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine: Disassembly, assembly, inspection, adjustment, troubleshooting of engine components (carburetor, ignition, cooling, lubrication, etc.) Transmission: Service, inspection, and repair of the gearbox and clutch assembly. Chassis And Suspension: Front fork, rear shock absorber, swingarm, linkage, steering system, wheel bearings, and related components. Brakes: Front and rear brake systems, including hydraulic lines, master cylinders, calipers, and pads. Electrical System Electrical System: Ignition system, lighting, battery, wiring diagrams, and component testing. Fuel System Fuel System: Fuel tank, fuel lines, and carburetor service and adjustment. Bodywork And Frame Bodywork And Frame: Frame inspection, fairings, seat, and other body components. Procedures Included Maintenance: Routine maintenance checks, lubrication, adjustments, and periodic service intervals. Troubleshooting: Systematic diagnostic procedures for common problems and failures. Repair: Step-by-step instructions for disassembly, repair, and reassembly of all major components. Installation: Procedures for installing new or replacement parts. Technical Depth Technical Depth: Comprehensive, from basic adjustments to complete engine rebuilds, with detailed explanations and diagrams. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Printable (high resolution implied by comprehensive coverage) Binding Type Binding Type: Digital (N/A for PDF) Paper Type Paper Type: Digital (N/A for PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, single-cylinder Displacement: 59.6 cc (typical for KX60 models) Bore X Stroke: 43.0 mm x 41.6 mm (typical) Cooling System: Air-cooled Performance Horsepower: Approx. 9-10 HP (estimated, exact figures vary by year and tuning) Torque: Not explicitly provided, but tuned for low-end torque suitable for youth riders. Fuel System Carburetor: Mikuni VM15SC (typical) Fuel Type: Unleaded gasoline mixed with 2-stroke oil (ratio specified in manual) 🔧 Transmission Standard Transmission Type: 6-speed manual Features Clutch Type: Wet multi-disc 📐 Dimensions Exterior Overall Length: Approx. 1620 mm (typical) Overall Width: Approx. 740 mm (typical) Overall Height: Approx. 1015 mm (typical) Weights Dry Weight: Approx. 63 kg (typical) Wheelbase: Approx. 1130 mm (typical) 🛡️ Safety Features Ratings Safety Features: Standard motocross safety features; emphasis on rider skill development. Active Features Braking System: Front and rear disc brakes for reliable stopping power. 💡 Technology Features Infotainment Infotainment System: None (This is a dedicated off-road racing motorcycle). Driver Assistance Driver Assistance Features: None (This is a dedicated off-road racing motorcycle). 🔧 Maintenance Service Intervals Oil Change Interval: Specific interval for gearbox oil change will be detailed in the manual, typically after initial break-in and then periodically. Spark Plug Replacement: Regular inspection and replacement based on usage and condition, as per manual recommendations. Air Filter Cleaning: Frequent cleaning and/or replacement of the air filter is critical for 2-stroke engines, especially in dusty off-road conditions. Fluid Specifications Gear Oil: Manual will specify SAE 10W-30 or SAE 10W-40 API GL-4 transmission oil for the gearbox. 2 Stroke Oil: High-quality 2-stroke motorcycle oil, premix or injection system, with specific ratio recommendations in the manual. Known Issues Clutch Wear: Common in high-performance off-road bikes; subject to wear due to aggressive riding. Manual will detail inspection and replacement. Carburetor Fouling: Can occur due to improper fuel/oil mixture or debris; manual provides cleaning and adjustment procedures. Suspension Seals: Front fork and rear shock seals can wear over time, leading to leaks; manual covers seal replacement and suspension service. 📚 Vehicle History Brand Heritage Kawasaki Motorsports: Kawasaki has a long...