MODEL APPLICATION Year
Model
2001
KX85-A1
2001
KX85-B1
2001
KX100-D1
2002
KX85-A2
2002
KX85-B2
2002
KX100-D2
2003
KX85-A3
2003
KX85-B3
2003
KX100-D3
2004
KX85-A4
2004
KX85-B4
2004
KX100-D4
2005
KX85-A5
2005
KX85-B5
2005
KX100-D5
Beginning Frame No. JKBKXFAC□1A000001 or JKBKX085AAA000001 JKVKXFBC□1A000001 or JKBKX085BBA000001 JKAKXTDC□1A000001 or JKAKX100DDA000001 JKBKXFAC□2A007001 or JKBKX085AAA007001 JKBKXFBC□2A003001 or JKBKX085BB1003001 JKAKXTDC□2A004001 or JKAKX100DDA004001 JKBKXFAC□3A015001 or JKBKX085AAA015001 JKBKXFBC□3A006001 or JKBKX085BBA006001 JKAKXTDC□3A008001 or JKAKS100DDA008001 JKBKXFAC□4A021001 JKBKXFBC□4A009001 or JKBKX085BBA009001 JKAKXTDC□4A012001 or JKAKX100DDA012001 JKBKXFAC□5A026001 or JKBKX085AAA026001 JKBKXFBC□5A012001 or JKBKX085BBA012001 JKAKXTDC□5A015001
Year
Model
2006
KX85A6F
2006
KX85B6F
2006
KX100D6F
2007
KX85A7F
2007
KX85B7F
2007
KX100D7F
2008
KX85A8F
2008
KX85B8F
2008
KX100D8F
2009
KX85A9F
2009
KX85B9F
2009
KX100D9F
2010
KX85AAF
2010
KX85BAF
Beginning Frame No. JKBKXFAC□6A031001 or JKBKX085AAA031001 JKBKXFBC□6A015001 or JKBKX085BBA015001 JKAKXTDC□6A018001 JKBKXFAC□7A036001 or JKBKX085AAA036001 JKBKXFBC□7A018001 or JKBKX085BBA018001 JKAKXTDC□7A021001 JKBKXFAC□8A040001 or JKBKX085AAA040001 JKBKXFBC□8A02001 or JKBKX085BBA020001 JKAKXTDC□8A023001 JKBKXFAC□9A045001 or JKBKX085AAA045001 JKBKXFBC□9A025001 or JKBKX085BBA025001 JKAKXTDC□9A026001 JKBKXFAC□AA049001 or JKBKX085AAA049001 JKBKXFBC□AA028001 or JKBKX085BBA028001
□:This digit in the frame number changes from one machine to another.
Part No.99924-1265-10
Printed in Japan
KX85 KX85-II KX100
Motorcycle Service Manual
Quick Reference Guide General Information
1 j
Fuel System
2 j
Cooling System
3 j
Engine Top End
4 j
Engine Right Side
5 j
Engine Removal/Installation
6 j
Engine Bottom End/Transmission 7 j
This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number 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 specific topic required.
Wheels/Tires
8 j
Final Drive
9 j
Brakes
10 j
Suspension
11 j
Steering
12 j
Frame
13 j
Electrical System
14 j
Appendix
15 j
KX85 KX85-II KX100
Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Consumer Products & Machinery 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.
Š 2000 Kawasaki Heavy Industries, Ltd.
10th Edition (1) : Apr. 8, 2009 (K)
LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L
ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot,feet gram(s) hour(s) liter(s)
lb m min N Pa PS psi r rpm TDC TIR V W Ω
pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) perminute top dead center total indicator reading volt(s) watt(s) ohm(s)
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts as to his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully 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 adversely affect safe operation. To get the longest life out of your motorcycle: Follow the Periodic Maintenance Chart in the Service Manual. Be alert for problems and non-scheduled maintenance. Use proper tools and genuine Kawasaki motorcycle 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 carefully. Don’t take shortcuts. Remember to keep complete records of maintenance and repair with dates and any new parts installed.
• • •
• •
How to Use this Manual In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the ignition coil section. Whenever you see symbols, heed their instructions! Always follow safe operating and maintenance practices.
DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate 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 This note symbol indicates points of par○ ticular interest for more efficient and convenient operation. a procedural step or work to be • Indicates 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 inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
GENERAL INFORMATION 1-1
General Information Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Periodic Maintenance Chart ................................................................................................... Torque and Locking Agent...................................................................................................... Special Tools and Sealants .................................................................................................... Cable, Wire and Hose Routing ...............................................................................................
1 1-2 1-5 1-7 1-13 1-15 1-19 1-23
1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, 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: (1) Dirt Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Disconnect the ground (–) cable from the battery before performing any disassembly operations on the motorcycle. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the cables from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive cable to the positive (+) terminal of the battery (3) Installation, Assembly Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever possible. (4) Tightening Sequence When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not given, tighten them evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws that are retaining the part a 1/4-turn before removing them. (5) Torque When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (6) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads. (7) Edges Watch for sharp edges, as they could cause injury through careless handling, especially during major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over. (8) High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (9) Gasket, O-ring Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks.
GENERAL INFORMATION 1-3 Before Servicing (10)Liquid Gasket, Locking Agent Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage. (11) Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. (12)Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and press it evenly over the base component. (13)Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s marks, press it in with the marks facing out. (14)Circlip, Retaining Ring, and Cotter Pin When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Install the circlip with its chamfered side facing load side as well. Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while the motorcycle is driven, leading to a major problem. (15)Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off and apply fresh grease or oil. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. (16)Direction of Engine Rotation To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as well. (17)Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are removed. Replacement parts will be damaged or lose their original function once they are removed. Therefore, always replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so designated in their respective text, they are replacement parts. (18)Electrical Leads All the electrical leads are either one-color or two-color. A two-color lead is identified first by the primary color and then the stripe color. For example, a yellow lead with thin red stripes is referred to as a “yellow/red” lead; it would be a “red/yellow” lead if the colors were reversed. Unless instructed otherwise, electrical leads must be connected to leads of the same color.
1-4 GENERAL INFORMATION Before Servicing Two-Color Electrical
(19)Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Bent Color change
Crack Dent Deterioration
Hardening Scratch Seizure
Warp Wear
(20)Specifications Specification terms are defined as follows: "Standards" show dimensions or performances which brand-new parts or systems have. "Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.
GENERAL INFORMATION 1-5 Model Identification KX85-A1 Left Side View
KX85-B1 Right Side View
1-6 GENERAL INFORMATION Model Identification KX100-D1 Left Side View
KX100-D1 Right Side View
GENERAL INFORMATION 1-7 General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Weight Curb Weight: Front Rear Fuel Tank Capacity Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Carburetion System Starting System Ignition System Ignition Timing
Spark Plug (Terminal profile) Port Timing Inlet: Open Close Scavenging: Open Close Duration Exhaust: Open Close
KX85-A1 ∼ A5, A6F ∼ AAF 1 820 mm (71.7 in.) 735 mm (28.9 in.) 1 055 mm (41.5 in.) 1 255 mm (49.4 in.) 340 mm (13.4 in.) 840 mm (33.1 in.) (KX85-A1 ∼ A8F) 65 kg (143 lb) (KX85A9F ∼) 69 kg (152 lb) 34 kg (75 lb) 35 kg (77 lb) 5.5 L (5.8 US qt) 2-stroke, single cylinder, piston reed valve Liquid-cooled 48.5 × 45.8 mm (1.91 × 1.80 in.) 84 cm³ (5.1 Cu in.) 10.0 (Low speed) 9.2 (High speed) Carburetor, KEIHIN PWK28 Primary kick CDI (Digital) 12° BTDC @12 000 r/min (rpm) (KX85-A1 ∼ A5) 12° BTDC @12 040 r/min (rpm) (KX85A6F ∼ ) NGK R6252K-105
KX85-B1 ∼ B5, B6F ∼ BAF 1 910 mm (75.2 in.) ← 1 105 mm (43.5 in.) 1 290 mm (50.8 in.) 380 mm (15.0 in.) 870 mm (34.3 in.) (KX85-B1 ∼ B8F) 68 kg (150 lb) (KX85B9F ∼) 71 kg (157 lb) 35 kg (77 lb) 36 kg (79 lb) ← ← ← ← ← ← ← ← ← ← ←(KX85-B1 ∼ B5) ←(KX85B6F ∼ ) ←
Full open –
← –
62.5° BBDC 62.5° ABDC 125°
← ← ←
87° (Low speed) 93.5° (High speed) 87° (Low speed) 93.5° (High speed)
← ← ← ←
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1-8 GENERAL INFORMATION General Specifications Items Duration Lubrication System Drive Train Primary Reduction System: Type Reduction Ratio Clutch Type Transmission: Type Gear Tatios: 1st 2nd 3rd 4th 5th 6th Final Drive System: Type Reduction Ratio Overall Drive Ratio Transmission Oil: Engine Oil: Grade Viscosity Capacity
KX85-A1 ∼ A5, A6F ∼ AAF 174° (Low speed) 187° (High speed) Petrol mix (32 : 1)
Gear 3.400 (68/20) Wet, multi disc
← ← ←
6-speed, constant mesh, return shift
←
2.538 1.875 1.500 1.250 1.090 0.956
(33/13) (30/16) (27/18) (25/20) (24/22) (22/23)
← ← ← ← ← ←
Chain drive 3.571 (50/14) 11.607 @Top gear
← 3.923 (51/13) 12.758 @Top gear
API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 (KX85-A1 ∼ A3) 0.65 L (0.69 US qt) (KX85-A4 ∼) 0.70 L (0.74 US qt)
Frame Type Steering Angle Caster (rake angle) Trail Front Tire: Size
Type
KX85-B1 ∼ B5, B6F ∼ BAF ← ← ←
Tubular, semi-double cradle 45° to either side 27° 89 mm (3.5 in.) 70/100-17 40M
Tube
← ← (KX85-B1 ∼ B3) 0.65 L (0.69 US qt) (KX85-B4 ∼) 0.70 L (0.74 US qt) ← ← ← 103 mm (4.1 in.) 70/100-19, (EU) 70/100-19 42M (KX85-B5 ∼) 70/100-19 42M ←
GENERAL INFORMATION 1-9 General Specifications Items Rear Tire: Size
Type Rim Size: Front Rear Front Suspension: Type Wheel Travel Rear Suspension: Type Wheel Travel Brake Type: Front and Rear Effective Disc Diameter: Front Rear
KX85-A1 ∼ A5, A6F ∼ AAF 90/100-14 49M
Tube 17 × 1.40 14 × 1.60
KX85-B1 ∼ B5, B6F ∼ BAF 90/100-16, (EU) 90/100-16 52M (KX85-B5 ∼) 90/100-16 52M ← 19 × 1.40 16 × 1.85
Telescopic fork 275 mm (10.8 in.)
← ←
Swing arm (Uni-trak) 275 mm (10.8 in.)
← ←
Single disc
←
202 mm (8.0 in.) 150 mm (5.9 in.)
← ←
Specifications are subject to change without notice, and may not apply to every country. (EU): Europe Model
1-10 GENERAL INFORMATION General Specifications KX100-D1 ∼ D5, D6F ∼ D9F
Items Dimmensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Weight Curb Mass: Front Rear Fuel Tank Capaciry Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Carburetion System Starting System Ignition System Ignition Timing Spark Plug Port Timing Inlet: Open Close Scavenging: Open Close Duration Exhaust: Open Close Duration Lubrication System
1 910 mm (75.2 in.) 735 mm (28.9 in.) 1 105 mm (43.5 in.) 1 290 mm (50.8 in.) 380 mm (15.0 in.) 870 mm (34.3 in.) (KX100-D1 ∼ D8F) 68 kg (150 lb) (KX100D9F) 71 kg (157 lb) 35 kg (77 lb) 36 kg (79 lb) 5.5 L (1.5 US qal) 2-stroke, single cylinder, piston reed valve Liquid-cooled 52.5 × 45.8 mm (2.1 × 1.8 in.) 99 cm³ (6.0 Cu in.) 9.6 (Low speed) 8.8 (High speed) Carburetor, KEIHIN PWK28 Primary kick CDI (Digital) (KX100-D1 ∼ D5) 15° BTDC @12 500 r/min (rpm) (KX100D6F ∼ ) 21.2° BTDC @10 000 r/min (rpm) NGK R6252K-105
Full open – 62° BBDC 62° ABDC 124° 87° (Low speed), 93.5° (High speed) 87° (Low speed), 93.5° (High speed) 174° (Low speed), 187° (High speed) Pertrol mix (32:1)
GENERAL INFORMATION 1-11 General Specifications KX100-D1 ∼ D5, D6F ∼ D9F
Items Drive Train Primary Reduction System: Type Reduction Ratio Clutch Type Transmission: Type Gear Tatios 1st 2nd 3rd 4th 5th 6th Final Drive System: Type Reduction Ratio Overall Drive Ratio Transmission Oil: Engine Oil: Grade Viscosity Capacity Frame Type Steering Angle Caster (rake angle) Trail Front Tire: Size Type Rear Tire: Size Type Rim Size: Front Rear Front Suspension: Type Wheel Travel
Gear 3.400 (68/20) Wet, multi disc 6-speed, constant mesh, return shift 2.538 1.875 1.500 1.250 1.090 0.956
(33/13) (30/16) (27/18) (25/20) (24/22) (22/23)
Chain drive 3.923 (51/13) 12.758 @Top gear
API SE, SF or SG API SH, SJ, SL or SM with JASO MA, MA1 or MA2 SAE 10W-40 (KX100-D1 ∼ D3) 0.65 L (0.69 US qt) (KX100-D4 ∼) 0.70 L (0.74 US qt) Tubular, single cradle 45° to either side 27° 103 mm (4.1 in.) 70/100-19, (EU) 70/100-19 42M (KX100-D5 ∼) 70/100-19 42M Tube 90/100-16, (EU) 90/100-16 52M (KX100-D5 ∼) 90/100-16 52M Tube 19 × 1.40 16 × 1.85 Telescopic fork 275 mm (10.8 in.)