Kawasaki KX100 - User manual

KX85

KX85-II

KX100

Motorcycle

Service Manual

This quick refe

rence guide will assist

you in locating a desired topic or pro-

cedure.

•Bend the pag

es back to match the

black tab of the desired chapter num-

ber with the black tab on the edge at

each table

of contents page.

•Refer to the sectional table of contents

for the exact pages to locate the spe-

cific to

pic required.

Quick Reference Guide

General Information 1

j

Periodic Maintenance 2

j

Fuel System 3

j

Cooling System 4

j

Engine Top End 5

j

Engine Right Side 6

j

Engine Removal/Installation 7

j

Engine Bottom End/Transmission 8

j

Wheels/Tires 9

j

Final Drive 10

j

Brakes 11

j

Suspension 12

j

Steering 13

j

Frame 14

j

Electrical System 15

j

Appendix 16

j

KX85

KX85-II

KX100

Motorcycle

Service Manual

transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,

without the prior written permission of Quality Assurance Division/Motorcycle & Engine Company/Kawasaki

Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible

care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation

to make such changes to products manufactured previously. See your Motorcycle dealer for the latest

information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time

of publication. Illustrations and photographs in this publication are intended for reference use only and may

not depict actual model component parts.

LIST OF ABBREVIATIONS

A ampere(s) KIPS Kawasaki Integrated Powervalve System

ABDC after bottom dead center km/h kilometers per hour

AC

alternating current

L

liter(s)

Ah ampere hour lb

pound(s)

ATDC after top dead center

m

meter(s)

BBDC before bottom dead center min minute(s)

BDC bottom dead center mph miles per hour

BTDC before top dead center N newton(s)

°C degree(s) Celsius oz ounce(s)

CDI Capacitor Discharge Ignition Pa pascal(s)

cmHg centimeters of mercury PS horsepower

cu in. cubic inch(s) psi pound(s) per square inch

DC direct current qt quart(s)

F farad(s) r revolution

°F degree(s) Fahrenheit

rpm

revolution(s) perminute

ft foot, feet

s

second(s)

g

gram(s)

TDC

top dead center

gal gallon(s) TIR total indicator reading

h hour(s) Vvolt(s)

HP horsepower(s) W watt(s)

in. inch(s) Ω ohm(s)

COUNTRY AND AREA CODES

AU Australia EUR Europe

CA Canada US United States

Foreword

This manual is designed primarily for use by

trained mechanics in a properly equipped shop.

However, it contains enough detail and basic in-

formation to make it useful to the owner who de-

sires to perform his o wn basic maintenance and

repair work. A basic knowledge of mechanics,

the proper use of tools, and workshop proce-

dures must be understood in order to carry out

maintenance and repair satisfactorily. When-

ever the owner has insufficient experience or

doubts his ability to do the work, all adjust-

ments, maintenance, and repair should be car-

ried out only by qualified mechanics.

In order to perform the work efficiently and

to avoid costly mistakes, read the text, thor-

oughly familiarize yourself with the procedures

before starting work, and then do the work care-

fully in a clean area. Whenever special tools or

equipment are specified, do not use makeshift

tools or equipment. Precision measurements

can only be made if the proper instruments are

used, and the use of substitute tools may ad-

versely affect safe operation.

To get the longest life out of your vehicle:

•

Follow the Periodic Maintenance Chart in the

Service Manual.

•

Be alert for problems and non-scheduled

maintenance.

•

Use proper tools and genuine Kawasaki Mo-

torcycle parts. Special tools, gauges, and

testers that are necessary when servicing

Kawasaki motorcycles are introduced by the

Service Manual. Genuine parts provided as

spare parts are listed in the Parts Catalog.

•

Follow the procedures in this manual care-

fully. Don’t take shortcuts.

•

Remember to keep complete records of main-

tenance and repair with dates and any new

parts installed.

How to Use This M

anual

In this manual, the product is divided into

its major systems and these systems make up

the manual’s c

hapters. The Quick Reference

Guide shows y ou all of the product’s system

and assists in locating their chapters. Each

chapter in t

urn has its own comprehensive Ta-

ble of Contents.

For example, if you want ignition coil informa-

tion, use the Quick Reference Guide to locate

the Electrical System chapter. Then, use the

Table of Contents on the first page of the chap-

ter to find the Ignition Coil section.

Whenever you see symbols, heed their in-

structions! Always follow safe operating and

maintenance practices.

DANGER

DANGER indicates a hazardous situa-

tion which, if not avoided, will result in

death or serious injury.

WARNING

WARNING indicates a hazardous situa-

tion which, if not avoided, could result

in death or serious injury.

NOTICE

NOTICE is used to address practices not

related to personal injury.

This manual contains four more symbols

which will help you distinguish different types

of information.

NOTE

○

NOTE ind icates information th at may help

or guide you in the operation or service of

the vehicle.

•

Indicates a procedural step or work to be

done.

○

Indicates a procedural sub-step or how to do

the work of the procedural step it follows. It

also precedes the text of a NOTE

.

Indicates a conditional step or what action to

take based on the results of the test or inspec-

tion in the procedural st

ep or sub-step it fol-

lows.

In most chapters an exploded view illustration

of the system component

s follows the Table of

Contents. In these illustrations you will find the

instructions indicating which parts require spec-

ified tightening t

orque, oil, grease or a locking

agent during assembly.

GENERAL INFORMATION 1-1

1

General Information

Table of Contents

Before Servicing ..................................................................................................................... 1-2

Model Identification................................................................................................................. 1-7

General Specifications............................................................................................................ 1-10

Unit Conversion Table ............................................................................................................ 1-16

1-2 G ENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly opera-

tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-

tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever

necessary. This section explains the items that require particular attention during the removal and

reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury

from possible sharp edges on the parts.

Solvent

Use a high flash-point solvent when cleaning parts. High

flash-point solvent should be used according to directions

of the solvent manufacturer.

Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or

other foreign materials entering i nto sealed areas during ve-

hicle disassembly can cause e xcessive wear and decrease

performance of the vehicle.

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the

parts according to the order the parts were disassembled

and clean the parts in order prior to assembly.

GENERAL INFORMATION 1-3

Before Servicing

Storage of Removed Parts

After all the parts including subassembly parts have been

cleaned, store the parts in a clean area. Put a clean cloth

or plastic sheet over the parts to protect from any foreign

materials that may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious ac-

cident. Visually inspect removed parts for corrosion, discol-

oration, or other damage. Refer to the appropriate sections

of this manual for service limits on individual parts. Replace

the parts if any damage has been found or if the part is be-

yond its service limit.

Replacement Parts

Replacement parts must be KAWASAKI genuine or

recommended by KAWASAKI. G askets, O-rings, oil seals,

grease seals, circlips, cotter pins or self-locking nuts must

be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassem-

bly, however, if assembly order is provided in this Service

Manual, follow the procedures given.

Tightening Sequence

Generally, when installing a part with several bolts, nuts,

or screws, start them all in their holes and tighten them to

a snug fit. Then tighten them according to the specified se-

quence to prevent case warpage or deformation which can

lead to malfunction. Conversely when loosening the bolts,

nuts, or screws, first loosen all of them by about a quar-

ter turn and then remove them. If the specified tightening

sequence is not indicated, tighten the fasteners alternating

diagonally.

1-4 G ENERAL INFORMATION

Before Servicing

Tightening Torque

Incorrect torque applied to a bolt, nut, or s crew may

lead to serious damage. Tighten fasteners to the specified

torque using a good quality torque wrench. Often, the

tightening sequence is followed twice-initial tightening and

final tightening with torque wrench.

All of the tightening torque values are for use with dry,

solvent - cleaned threads unless otherwise indicated. If a

fastener which should have dry, clean threads gets contami-

nated with lubricant, etc., applying even the specified torque

could damage it.

Force

Use common sense during disassembly and assembly,

excessive force can cause expensive or hard to repair dam-

age. When necessary, remove screws that have a non

-permanent locking agent applied using an impact driver.

Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O -ring

Hardening, shrinkage, or damage of both gaskets

and O-rings after disassembly can reduce sealing per-

formance. Remove old gaskets and clean the sealing

surfaces thoroughly so that no gasket material or other

material remains. Install new gaskets and replace used

O-rings when re-assembling.

Liquid Gasket, Non-permanent Locking Agent

For applications that require Liquid Gasket or a

Non-permanent Locking Agent, clean the surfaces so

that no oil residue remains before applying liquid gasket or

non-permanent locking agent. Do not apply them exces-

sively. Excessive application can clog oil passages and

cause serious damage.

Press

For items such as bearings or oil seals that must be

pressed into place, apply small amount of oil to the con-

tact area. Be sure to maintain proper alignment and use

smooth movements w hen installing.

GENERAL INFORMATION 1-5

Before Servicing

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is

absolutely necessary. Replace with new ones whenever

removed. Press bearings with the manufacturer and size

marks facing out. Press the bearing into place by putting

pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between

the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal

is necessary. Replace with new ones whenever removed.

Press new oil seals with manufacture and size marks facing

out. Make sure the seal is aligned properly when installing.

Apply specified grease to the lip of seal before installing

the seal.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new

ones. Take care not to open the clip excessively when in-

stalling to prevent deformation.

Lubrication

It is important to lubricate rotating or sliding parts during

assembly to minimize wear during initial operation. Lubri-

cation points are called out throughout this manual, apply

the specific oil or grease as specified.

1-6 G ENERAL INFORMATION

Before Servicing

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play

amount of rotating direction will affect the adjustment. Ro-

tate the crankshaft to positive direction (clockwise viewed

from output side).

Electrical Leads

A two-color lead is identified first by the primary color and

then the stripe color. Unless instructed otherwise, electrical

leads must be connected to those of the same color.

Instrument

Use a meter that has enough accuracy for an accurate

measurement. Read the manufacture’s instructions thor-

oughly before using the meter. Incorrect values may lead

to improper adjustments.

GENERAL INFORMATION 1-7

Model Identification

KX85CE Left Side View

KX85CE Right Side View

1-8 G ENERAL INFORMATION

Model Identification

KX85DE Left Side View

KX85DE Right Side View

GENERAL INFORMATION 1-9

Model Identification

KX100FE Left Side View

KX100FE Right Side View

Frame Number Engine Number

1-10 GENERAL INFORMATION

General Specifications

Items

KX85CE

KX85DE

Dimensions

Overall Length 1 830 mm (72.04 in.) 1 920 mm (75.59 in.)

Overall Width 765 mm (30.1 in.) ←

Overall Height 1 100 mm (43.31 in.) 1 150 mm (45.28 in.)

Wheelbase

1 265 mm (49.80 in.) 1 310 mm (51.57 in.)

Road Clearance 290 mm (11.4 in.) 330 mm (13.0 in.)

Seat Height 830 mm (32.7 in.) 870 mm (34.3 i n.)

Curb Mass: 75 kg (165 lb) 77 kg (169 lb)

Front 36 kg (79 lb) 37 kg (82 lb)

Rear 39 kg (86 lb) 40 kg (88 lb)

Fuel Tank Capacity 5L(1USqt) ←

Engine

Type 2-stroke, single cylinder, piston reed

valve

←

Cooling System

Liquid-cooled ←

Bore and Stroke 48.5 × 45.8 mm (1.91 × 1.80 in.) ←

Displacement 84 cm³ (5.1 Cu in.) ←

Compression Ratio 10.9 (Low speed) ←

9.0 (High speed) ←

Fuel System Carburetor, KEIHIN PWK28 ←

Fuel Type:

Minimum Octane Rating:

Research Octane

Number (RON)

(AU, EUR) 95

←

Antiknock Index (RON

+MON)/2

(US, CA) 90 –

Starting System

Primary kick ←

Ignition System CDI (Digital) ←

Timing Advance Electronically advanced ←

Ignition Timing 12° BTDC at 11 320 r/min (rpm) ←

Spark Plug NGK R6252K-105

←

Terminal

Solid-post

←

Port Timing

Intake:

Open Full open ←

Close – –

Scavenging:

Open 63.8° BBDC ←

Close 63.8° ABDC ←

Duration 127.6° ←

Exhaust:

Open 79° (Low speed) ←

93.6° (High speed) ←

Close 79° (Low speed) ←

93.6° (High speed) ←

GENERAL INFORMATION 1-11

General Specifications

Items KX85CE KX85DE

Duration 158° (Low speed) ←

187.2° (High speed)

←

Lubrication System Petrol mix (32 : 1)

←

Drive Train

Primary Reduction System:

Type Gear ←

Reduction Ratio 3.400 (68/20) ←

Clutch Type

Wet, multi disc ←

Transmission:

Type 6-speed, constant mesh, return shift ←

Gear Tatios:

1st 2.538 (33/13) ←

2nd 1.875 (30/16) ←

3rd

1.500 (27/18)

←

4th

1.250 (25/20)

←

5th

1.090 (24/22)

←

6th 0.956 (22/23) ←

Final Drive System:

Type Chain drive ←

Reduction Ratio 3.571 (50/14) 3.923 (51/13)

Overall Drive Ratio 11.607 at Top gear 12.758 at Top gear

Transmission Oil:

Type

API SG, SH, SJ, SL or SM with JASO

MA, MA1 or MA2

←

Viscosity

SAE 10W-40

←

Capacity 0.7 L (0.7 US qt) ←

Frame

Type Tubular, semi-double cradle ←

Steering Angle 45° to either side ←

Caster (Rake Angle) 29° ←

Trail 97 mm (3.8 in.) 108 mm (4.25 in.)

Front Wheel:

Tire Size 70/100-17 40M 70/100-19 42M

Tire Make/T ype DUNLOP MX51F, Tube type ←

Rim Size 17 × 1.40 19 × 1.40

Rear Wheel:

Tire Size 90/100-14 49M 90/100-16 52M

Tire Make/T ype DUNLOP MX51, Tube type ←

Rim Size 14 × 1.60 16 × 1.85

Front Suspension:

Type Telescopic fork (upside down) ←

Wheel Travel 275 mm (10.8 in.) ←

1-12 GENERAL INFORMATION

General Specifications

Items

KX85CE

KX85DE

Rear Suspension:

Type Swing arm (Uni-trak) ←

Wheel Travel 275 mm (10.8 in.) ←

Brake Type:

Front and Rear

Single disc

←

Effective Disc Diameter:

Front 202 mm (7.95 in.) ←

Rear 150 mm (5.91 in.) ←

Specifications are subject to change without notice, and may not apply to every country.

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