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Kawasaki KX85 Service Manual

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Service Manual


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  • Page 1 KX85 KX85-II KX100 Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Fuel System Cooling System Engine Top End Engine Right Side Engine Removal/Installation Engine Bottom End/Transmission 7 j Wheels/Tires Final Drive Brakes 10 j Suspension 11 j Steering 12 j Frame 13 j Electrical System 14 j Appendix 15 j This quick reference guide will assist...
  • Page 5 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. © 2000 Kawasaki Heavy Industries, Ltd. 10th Edition (1) : Apr. 8, 2009 (K)
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: How To Use This Manual

    Be alert for problems and non-scheduled This manual contains four more symbols maintenance. which will help you distinguish different types • Use proper tools and genuine Kawasaki mo- of information. torcycle parts. Special tools, gauges, and testers that are necessary when servicing NOTE ○...
  • Page 9: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Periodic Maintenance Chart ....................1-13 Torque and Locking Agent...................... 1-15 Special Tools and Sealants ....................1-19 Cable, Wire and Hose Routing ....................1-23...
  • Page 10: Before Servicing

    1-2 GENERAL 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.
  • Page 11: General Information

    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 dam- age. (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.
  • Page 12 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 Crack Hardening...
  • Page 13: Model Identification

    GENERAL INFORMATION 1-5 Model Identification KX85-A1 Left Side View KX85-B1 Right Side View...
  • Page 14 1-6 GENERAL INFORMATION Model Identification KX100-D1 Left Side View KX100-D1 Right Side View...
  • Page 15: General Specifications

    380 mm (15.0 in.) Seat Height 840 mm (33.1 in.) 870 mm (34.3 in.) (KX85-B1 ∼ B8F) (KX85-A1 ∼ A8F) 65 kg (143 lb) Dry Weight 68 kg (150 lb) (KX85A9F ∼) 69 kg (152 lb) (KX85B9F ∼) 71 kg (157 lb)
  • Page 16 API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2 ← Viscosity SAE 10W-40 (KX85-A1 ∼ A3) 0.65 L (0.69 US qt) (KX85-B1 ∼ B3) 0.65 L Capacity (0.69 US qt) (KX85-A4 ∼) 0.70 L (0.74 US qt) (KX85-B4 ∼) 0.70 L...
  • Page 17 GENERAL INFORMATION 1-9 General Specifications KX85-A1 ∼ A5, A6F ∼ AAF KX85-B1 ∼ B5, B6F ∼ BAF Items Rear Tire: Size 90/100-14 49M 90/100-16, (EU) 90/100-16 52M (KX85-B5 ∼) 90/100-16 52M ← Type Tube Rim Size: Front 17 × 1.40 19 ×...
  • Page 18 1-10 GENERAL INFORMATION General Specifications KX100-D1 ∼ D5, D6F ∼ D9F Items Dimmensions Overall Length 1 910 mm (75.2 in.) Overall Width 735 mm (28.9 in.) Overall Height 1 105 mm (43.5 in.) Wheelbase 1 290 mm (50.8 in.) Road Clearance 380 mm (15.0 in.) Seat Height 870 mm (34.3 in.)
  • Page 19 GENERAL INFORMATION 1-11 General Specifications KX100-D1 ∼ D5, D6F ∼ D9F Items 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 2.538 (33/13) 1.875 (30/16) 1.500 (27/18) 1.250 (25/20) 1.090 (24/22)
  • Page 20 1-12 GENERAL INFORMATION General Specifications KX100-D1 ∼ D5, D6F ∼ D9F Items Rear Suspension: Type Swingarm (Uni-trak) Wheel Travel 275 mm (10.8 in.) Brake Type: Front and Rear Single disc Effective Disc Diameter: Front 202 mm (8.0 in.) Rear 150 mm (5.9 in.) Specifications are subject to change without notice, and may not apply to every country.
  • Page 21: Periodic Maintenance Chart

    GENERAL INFORMATION 1-13 Periodic Maintenance Chart The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. FREQUENCY Each Every 3 Every 5 Every 10 race races races races required OPERATION (2.5 hr) (7.5 hr) (12.5 hr) (25 hr)
  • Page 22 1-14 GENERAL INFORMATION Periodic Maintenance Chart FREQUENCY Each Every 3 Every 5 Every 10 race races races races required OPERATION (2.5 hr) (7.5 hr) (12.5 hr) (25 hr) Front fork oil - change 1st time after 2 races, then every 5 races •...
  • Page 23: Torque And Locking Agent

    GENERAL INFORMATION 1-15 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the "Remarks" column mean: L: Apply a non-permanent locking agent to the threads. Lh: Left-hand threads M: Apply molybdenum disulfide grease.
  • Page 24 13 in·lb Lever Shaft Retaining Bolt 0.55 48 in·lb Lever Assembly Mounting Screw 0.65 56 in·lb (KX85-A4 ∼/B4 ∼) Engine Removal/Installation Engine Mounting Nuts Engine Mounting Bracket Nuts Swing Arm Pivot Shaft Nut Engine Bottom End/Transmission Engine Oil Drain Plug...
  • Page 25 GENERAL INFORMATION 1-17 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Brake Lever Pivot Bolt 0.60 52 in·lb Brake Lever Adjust Locknut 0.50 43 in·lb Front Master Cylinder Clamp Bolts 0.90 78 in·lb Caliper Mounting Bolts (front, rear) Disc Bolts (front, rear) 87 in·lb Rear Master Cylinder Mounting Bolts...
  • Page 26 1-18 GENERAL INFORMATION Torque and Locking Agent The table on the right relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
  • Page 27: Special Tools And Sealants

    GENERAL INFORMATION 1-19 Special Tools and Sealants Fuel Level Gauge, M18 × 1.0: Compression Gauge, 20 kgf/cm²: 57001-122 57001-221 Bearing Puller Adapter: Flywheel Puller, M12 × 1.75: 57001-136 57001-252 Inside Circlip Pliers: Bearing Driver, 32: 57001-143 57001-382 Outside Circlip Pliers: Piston Pin Puller Assembly: 57001-144 57001-910...
  • Page 28 1-20 GENERAL INFORMATION Special Tools and Sealants Bead Breaker Assembly: Head Pipe Outer Race Driver, 46.5: 57001-1072 57001-1106 Head Pipe Outer Race Press Shaft: Head Pipe Outer Race Remover ID > 37 mm: 57001-1075 57001-1107 Steering Stem Bearing Driver Adapter, 29.7: Bearing Driver Set: 57001-1092 57001-1129...
  • Page 29 GENERAL INFORMATION 1-21 Special Tools and Sealants Fork Outer Tube Weight: Fork Spring Holder: 57001-1218 57001-1286 Jack: Fork Oil Level Gauge: 57001-1238 57001-1290 Clutch Holder: Fork Piston Rod Puller, M10 × 1.0: 57001-1243 57001-1298 Bearing Remover Shaft, 9: Flywheel Holder: 57001-1265 57001-1313 Bearing Remover Head, 10 ×...
  • Page 30 1-22 GENERAL INFORMATION Special Tools and Sealants Hand Tester: Gear Holder: 57001-1394 57001-1602 Fork Cylinder Holder: Flywheel & Pulley Holder: 57001-1413 57001-1605 Peak Voltage Adapter: Liquid Gasket, TB1211: 57001-1415 56019-120 Lead Wire - Magneto Lead Adapter: Liquid Gasket, TB1105B: 57001-1469 92104-002 Bearing Puller Adapter: 57001-1526...
  • Page 31: Cable, Wire And Hose Routing

    GENERAL INFORMATION 1-23 Cable, Wire and Hose Routing 1. Run the throttle cable and engine stop button lead through the clamp. 2. Do not pinch the throttle cable between the fuel tank and frame. 3. Adheve the damper on the frame pipe. 4.
  • Page 32 1-24 GENERAL INFORMATION Cable, Wire and Hose Routing 1. Engine Stop Button Ground Lead (B) 11. Ignition Coil 2. Run the engine stop button lead through 12. Ignition Coil Primary Lead the clamp for throttle cable. 13. Bundle the harness under the frame pipe. 3.
  • Page 33 GENERAL INFORMATION 1-25 Cable, Wire and Hose Routing 1. Tighten the CDI unit and engine stop but- 8. Carburetor Air Vent Tube ton ground terminals together with lower 9. Magneto Lead ignition coil installation bolt. 10. Do not cross the carburetor air vent tube 2.
  • Page 34 1-26 GENERAL INFORMATION Cable, Wire and Hose Routing 1. Front Brake Master Cylinder 9. Banjo Bolt 2. Brake Lever 10. Rear Brake Master Cylinder 3. Banjo Bolt 11. Brake Pedal 4. Front Brake Hose 12. Brake Hose Guide 5. Front Brake Caliper 13.
  • Page 35 GENERAL INFORMATION 1-27 Cable, Wire and Hose Routing 1. Route the water hose so that it does not touch the exhaust pipe. 2. Route the water hose between 3 engine mounting brackets. 3. Route the water hose noting the bend of it. 4.
  • Page 37: Fuel System

    FUEL SYSTEM 2-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Throttle Grip and Cable ......................Free Play Inspection ......................Free Play Adjustment......................Installation Notes ......................Cable Lubrication ......................Cable Inspection ....................... Carburetor ..........................Idle Speed Inspection ....................... Idle Speed Adjustment...................... Main Jet Replacement Notes....................
  • Page 38: Exploded View

    2-2 FUEL SYSTEM Exploded View 1. Throttle Cable T1: 1.0 N·m (0.10 kgf·m, 9 in·lb) 2. Pilot Screw T2: 8.8 N·m (0.90 kgf·m, 78 in·lb) 3. Needle Jet T3: 1.5 N·m (0.15 kgf·m, 13 in·lb) 4. Main Jet Holder CL: Apply cable lubricant 5.
  • Page 39 FUEL SYSTEM 2-3 Exploded View 12. Fuel Tap (KX85A6F ∼/B6F ∼, KX100D6F 1. Fuel Tank Cap ∼) 2. Gasket 3. Fuel Filler T1: 0.8 N·m (0.08 kgf·m, 7 in·lb) 4. Fuel Tank T2: 8.8 N·m (0.90 kgf·m, 78 in·lb) 5. Fuel Tap T3: 3.0 N·m (0.31 kgf·m, 27 in·lb) 6.
  • Page 40: Specifications

    2-4 FUEL SYSTEM Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle grip free play and Cable – – – Carburetor Make/type KEIHIN PWK28 – – – Main Jet: KX85A/B #140 – – – KX100D #138 –...
  • Page 41: Throttle Grip And Cable

    FUEL SYSTEM 2-5 Throttle Grip and Cable If the throttle grip has excessive free play due to cable stretch or misjudgments, there will be a delay in throttle re- sponse. Also, the throttle valve may not open fully at full throttle.
  • Page 42: Installation Notes

    2-6 FUEL SYSTEM Throttle Grip and Cable Installation Notes • Install the throttle cable in accordance with the Cable, Wire and Hose Routing section in the General Informa- tion chapter. • After the installation, adjust each cable properly. Cable Lubrication •...
  • Page 43: Carburetor

    FUEL SYSTEM 2-7 Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine, there are two general types of carbure- tor trouble: too rich a mixture (too much fuel), and too lean a mixture (too little fuel). Such trouble can be caused by dirt, wear, maladjustment, or improper fuel level in the float chamber.
  • Page 44: Service Fuel Level Inspection

    2-8 FUEL SYSTEM Carburetor • Turn the fuel tap to the OFF position. • Remove the fuel tank. • Place a suitable container beneath the carburetor drain plug. • Remove the carburetor (see Carburetor Removal). • Remove the drain plug to drain the carburetor. •...
  • Page 45: Service Fuel Level Adjustment

    FUEL SYSTEM 2-9 Carburetor Service Fuel Level Adjustment WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 46: Removal

    2-10 FUEL SYSTEM Carburetor • Place a suitable container beneath the carburetor. • Turn the fuel tap to the OFF position. • Remove the drain plug [A] from the bottom of the float bowl and check for water or dirt in the fuel. If any water or dirt comes out, clean the carburetor (see Carburetor Cleaning), fuel tap and fuel tank (see Fuel Tap, Fuel Tank Cleaning).
  • Page 47: Installation

    FUEL SYSTEM 2-11 Carburetor Installation • Being careful not to bend or otherwise damage the jet needle [B], insert the throttle valve assembly [A] into the carburetor body. ○ Check to see that the throttle valve goes all the way down into the carburetor body, and slides smoothly.
  • Page 48: Disassembly

    2-12 FUEL SYSTEM Carburetor Disassembly WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks;...
  • Page 49: Cleaning

    FUEL SYSTEM 2-13 Carburetor Cleaning WARNING Gasoline and low-flash point solvents can be flammable and/or explosive and cause severe burns. Clean the carburetor in a well ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light.
  • Page 50 2-14 FUEL SYSTEM Carburetor • Clean the carburetor (see cleaning). • Check the plastic tip [A] of the float valve needle [B]. It should be smooth without any grooves, scratches, or tears. If the plastic tip is damaged [C], replace the needle. •...
  • Page 51: Air Cleaner

    FUEL SYSTEM 2-15 Air Cleaner Air Cleaner Element Removal • Remove the side cover. • Remove the wing bolt [A] and pull out the element [B]. Air Cleaner Element Installation • Coat the lip of the element [A] with a thick layer of all purpose grease [B] to assure a complete seal.
  • Page 52: Air Cleaner Housing Removal

    2-16 FUEL SYSTEM Air Cleaner • Remove the air cleaner element, and separate the ele- ment [A] from the frame [B]. • Clean the element in a bath of a high flash-point solvent, and squeeze the element dry. • Check all the parts of the element for visible damage. If any part of the element is damaged, replace it.
  • Page 53: Fuel Tank

    FUEL SYSTEM 2-17 Fuel Tank Fuel Tank Removal • Remove: Seat (see Frame chapter) Air Scoop [A] • Turn the fuel tap to the OFF position. • Pull the fuel hose off the fuel tap. WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions.
  • Page 54: Fuel Tap Inspection

    2-18 FUEL SYSTEM Fuel Tank Fuel Tap Inspection • Remove the fuel tap. • Check the fuel tap filter screen for any breaks or deterio- ration. If the fuel tap screen has any breaks or is deteriorated, it may allow dirt to reach the carburetor, causing poor run- ning.
  • Page 55: Reed Valve

    FUEL SYSTEM 2-19 Reed Valve Removal • Remove the carburetor (see Carburetor Removal). • Remove the carburetor holder [A] mounting Bolts, and move the rearward. • Take the reed valve assembly [B] out of the cylinder. Installation Note Torque - Carburetor Holder Mounting Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) Inspection •...
  • Page 56: Fuel Hose

    2-20 FUEL SYSTEM Fuel Hose Fuel Hoses and Connections Inspection ○ Check the fuel hose periodically in accordance with the Periodic Maintenance Chart, and if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank and check the fuel hose.
  • Page 57 COOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View........................Cooling System ........................Specifications ......................... Coolant ........................... Coolant Level Inspection....................Coolant Deterioration Inspection..................Coolant Draining ....................... Coolant Filling ........................Cooling System Pressure Testing ..................Cooling System Flushing ....................Water Pump..........................Water Pump Cover Removal ....................
  • Page 58: Exploded View

    3-2 COOLING SYSTEM Exploded View 1. Air Bleeder Bolt T1: 1.5 N·m (0.15 kgf·m, 13 in·lb) 2. Radiator T2: 8.8 N·m (0.90 kgf·m, 78 in·lb) 3. Water Hoses T3: 7.0 N·m (0.70 kgf·m, 61 in·lb) 4. Water Pump Cover T4: 5.4 N·m (0.55 kgf·m, 48 in·lb) 5.
  • Page 59 COOLING SYSTEM 3-3 Cooling System The cooling system is a pressurized forced circulation type. When the engine load varies, this sys- tem controls the engine temperature within narrow limits where the engine operates most efficiently. In this way the engine performs stably in various riding conditions, and possesses high durability. 1.
  • Page 60: Specifications

    3-4 COOLING SYSTEM Specifications Item Standard Coolant Type Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green Mixed Ratio Soft water 50%, coolant 50% Freezing Point − 35°C (− 31°F) Total Capacity 0.67 L (0.71 US qt) Radiator...
  • Page 61: Coolant

    COOLING SYSTEM 3-5 Coolant Check the coolant level each day before riding the motor- cycle, and replenish coolant if the level is low. Change the coolant in accordance with the Periodic Maintenance Chart (see General Information chapter). WARNING Hot engine coolant can cause serious burns. To avoid burns, do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot.
  • Page 62: Coolant Draining

    3-6 COOLING SYSTEM Coolant Coolant Draining WARNING Coolant can be extremely hot and cause severe burns, is toxic and very slippery. Do not remove the radiator cap or attempt to change the coolant when the engine is hot; allow it cool completely. Immediately wipe any spilled coolant from tires, frame, engine or other painted parts.
  • Page 63 COOLING SYSTEM 3-7 Coolant Recommended Coolant Type: Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color: Green Mixed ratio: Soft water 50%, Coolant 50% Freezing point: − 35°C (− 31°F) Total amount: 0.67 L (0.71 US qt) NOTE...
  • Page 64: Cooling System Pressure Testing

    3-8 COOLING SYSTEM Coolant Cooling System Pressure Testing Any time the system slowly loses coolant, inspect for leaks. NOTICE During pressure testing, do not exceed the pres- sure for which the system is designed to work. The maximum pressure is 125 kPa (1.25 kgf/cm², 18 psi). •...
  • Page 65: Water Pump

    COOLING SYSTEM 3-9 Water Pump Water Pump Cover Removal • Drain the coolant (see Coolant Draining). • Loosen the cooling hose clamps, and disconnect the cool- ing hoses [A] on the water pump cover. • Remove the water pump cover bolts [B], and remove the water pump cover [C].
  • Page 66: Water Pump Shaft Removal

    3-10 COOLING SYSTEM Water Pump Water Pump Shaft Removal • Remove: Right Engine Cover (see Engine Right Side chapter) Primary Gear [A] (see Engine Right Side chapter) • Pull out the water pump shaft [B]. Water Pump Seal Removal • Remove: Impeller (see Impeller Removal) Right Engine Cover (see Engine Right Side chapter)
  • Page 67: Radiator

    COOLING SYSTEM 3-11 Radiator Radiator Removal • Drain the coolant by removing the coolant drain plug (Wa- ter Pump) • Remove: Air Scoop Fuel Tank (Move back) Hose Clamps (Loosen) Breather Hose Upper End [A] Water Hose Ends [B] Radiator Screen [C] Radiator Mounting Bolts/Screw [D] Radiator [E] Radiator Installation...
  • Page 68: Radiator Cap Inspection

    3-12 COOLING SYSTEM Radiator Radiator Cap Inspection • Check the condition of the valve spring [B], and the top and bottom valve seals [A] of the radiator cap. If any one of them shows visible damage, replace the cap. • Wet the top and bottom valve seals with water or coolant to prevent pressure leaks.
  • Page 69 ENGINE TOP END 4-1 Engine Top End Table of Contents Exploded View........................Specifications ......................... Cylinder Head......................... Compression Pressure Measurement ................Removal..........................Installation......................... Warp Inspection ........................ Cylinder ..........................Cylinder Removal......................Cylinder Installation......................Piston Removal......................... Piston Installation......................Cylinder Wear Inspection....................Piston Diameter Measurement ..................Piston/Cylinder Clearance Inspection ................
  • Page 70: Exploded View

    4-2 ENGINE TOP END Exploded View 1: KIPS Chamber Vent Tube (KX85A6F ∼/B6F ∼, KX100D6F ∼ ) T1: 3.9 N·m (0.40 kgf·m, 35 in·lb) T2: 5.2 N·m (0.53 kgf·m, 46 in·lb) T3: 25 N·m (2.5 kgf·m, 18 ft·lb) T4: 29 N·m (3.0 kgf·m, 22 ft·lb) T5: 8.8 N·m (0.90 kgf·m, 78 in·lb) O: Apply 2 stroke-racing oil.
  • Page 71: Specifications

    48.439 ∼ 48.454 mm (1.9070 ∼ 1.9076 in.) KX85A/B 48.29 mm (1.90 in.) 48.444 ∼ 48.459 mm (1.9072 ∼ 1.9078 in.) 48.29 mm (1.90 in.) (KX85-A4 ∼/B4 ∼) 52.435 ∼ 52.450 mm (2.0644 ∼ 2.0650 in.) KX100D 52.29 mm (2.06 in.) Piston/cylinder Clearance 0.061 ∼...
  • Page 72: Cylinder Head

    4-4 ENGINE TOP END Cylinder Head Compression Pressure Measurement • Start the engine. • Thoroughly warm up the engine so that the engine oil be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. •...
  • Page 73: Installation

    ENGINE TOP END 4-5 Cylinder Head Installation • Replace the head gasket with a new one. • Scrape out any carbon and clean the head with a high flash-point solvent. • Check the head water jacket for a crust of minerals and rust and remove them if necessary.
  • Page 74: Cylinder

    4-6 ENGINE TOP END Cylinder Cylinder Removal • Drain the coolant (see Cooling System chapter). Be sure to remove the cylinder drain plug. • Remove the following. Cylinder Head (see Cylinder Head Removal) Carburetor (see Fuel System chapter) Radiator Hose Upper End KIPS Cover Muffler Holding Springs E-clip [A]...
  • Page 75: Piston Removal

    Don’t allow such particles to fall onto the cylinder walls. • The top [A] and second [B] rings are identical in KX100 model, But they are different in KX85 model. ○ The mark on the ring are as follows; KX85A/B-...
  • Page 76: Cylinder Wear Inspection

    4-8 ENGINE TOP END Cylinder ○ Install the ring so that the pin [A] in the piston ring groove is between the ends of the piston ring. • Apply 2-stroke engine oil to the connecting rod needle bearing and the piston pin. •...
  • Page 77: Piston Diameter Measurement

    If the measurement is under the service limit, replace the piston. Piston Diameter Standard: KX85-A1 ∼ A3/B1 ∼ B3 48.439 ∼ 48.454 mm (1.9070 ∼ 1.9076 in.) KX85-A4 ∼/B4 ∼ 48.444 ∼ 48.459 mm (1.9072 ∼ 1.9078 in.) 52.435 ∼...
  • Page 78: Piston Ring, Piston Ring Groove Inspection

    Measure the piston diameter and cylinder diameter as just described. Piston/Cylinder Clearance KX85-A1 ∼ A3/B1 ∼ B3: 0.061 ∼ 0.071 mm (0.0024 ∼ 0.0028 in.) KX85-A4 ∼/B4 ∼: 0.056 ∼ 0.066 mm (0.0022 ∼ 0.0026 in.) KX100D: 0.065 ∼...
  • Page 79: Piston Ring End Gap Inspection

    ENGINE TOP END 4-11 Cylinder Piston Ring Groove Width Standard: Top: 1.01 ∼ 1.03 mm (0.0398 ∼ 0.0406 in.) KX85A/B 1.03 ∼ 1.05 mm (0.0406 ∼ 0.0413 in.) KX100D 1.01 ∼ 1.03 mm (0.0398 ∼ 0.0406 in.) Second: Service Limit: Top: KX85A/B 1.11 mm (0.0437 in.)
  • Page 80 If there is any doubt as to the condition of a needle bear- ing, replace the bearing and piston pin. Piston Pin Diameter Standard: KX85, KX100 14.000 ∼ 13.995 mm (0.5512 ∼ 0.5510 in.) Service Limit: KX85, KX100 13.965 mm (0.5498 in.) Piston Pin Hole Diameter Standard: KX85, KX100 14.040 ∼...
  • Page 81: Exhaust Valve (Kips)

    ENGINE TOP END 4-13 Exhaust Valve (KIPS) Removal • Remove: Carburetor Cylinder Head Cylinder • Take out the screws [A] and remove the cover [B]. • Pull the valve assembly [A] out. • Unscrew the bolt [A] and remove the operating rod and the lever [B].
  • Page 82 4-14 ENGINE TOP END Exhaust Valve (KIPS) • Install the butterfly valve [A] on the holder [B], with a pin [C]. • Install the pin [D] in the slide valve [E], carefully the direc- tion of the brim [F]. • Place the slide valve on the holder as shown.
  • Page 83: Muffler

    ENGINE TOP END 4-15 Muffler Removal • Remove the left side cover and scoop. • Remove the muffler mounting bolts [A] • Pull the muffler body to backward. • Remove: Louver Exhaust Pipe Mounting Bolt [A] Exhaust Pipe Mounting Springs [B] •...
  • Page 85 5-15 Clutch Hub Spline Inspection.................... 5-15 Primary Gear .......................... 5-16 Removal (KX85-A1 ∼ A5/B1 ∼ B5, KX100-D1 ∼ D5)............5-16 Installation (KX85-A1 ∼ A5/B1 ∼ B5, KX100-D1 ∼ D5)............5-16 Primary Gear Removal (KX85A6F ∼/B6F ∼, KX100D6F ∼ ) ..........
  • Page 86: Exploded View

    5-2 ENGINE RIGHT SIDE Exploded View 1: KX85-A1 ∼ A5/B1 ∼ B5, KX100-D1 ∼ D5 T1: 9.3 N·m (0.95 kgf·m, 82 in·lb) T2: 88 N·m (9.0 kgf·m, 65 ft·lb) T3: 49 N·m (5.0 kgf·m, 36 ft·lb) CL: Apply Cable lubricant.
  • Page 87 2. Kick Gear T7: 5.4 N·m (0.55 kgf·m, 48 in·lb) 3. Ratchet T8: 12 N·m (1.2 kgf·m, 104 in·lb) 4. Lever Shaft (KX85-A1 ∼ A3/B1 ∼ B3, G: Apply grease. KX100-D1 ∼ D3) H: Apply high temperature grease. T1: 7.0 N·m (0.70 kgf·m, 61 in·lb) L: Apply a non-permanent locking agent.
  • Page 88: Specifications

    5-4 ENGINE RIGHT SIDE Specifications Item Standard Service Limit 8 ∼ 13 mm (0.3 ∼ 0.5 in.) Clutch Lever Free Play – – – Clutch 2.8 ∼ 2.9 mm (0.110 ∼ 0.114 in.) Friction Plate Thickness 2.7 mm (0.106 in.) Friction and Steel Plate Warp 0.15 mm (0.006 in.) or less 0.3 mm (0.012 in.)
  • Page 89: Clutch Cable

    ENGINE RIGHT SIDE 5-5 Clutch Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns.
  • Page 90: Clutch Release Lever Angle Inspection And Adjustment

    5-6 ENGINE RIGHT SIDE Clutch Cable Clutch Release Lever Angle Inspection and Adjustment If the clutch slips or the action at the lever feels heavy despite proper clutch lever free play adjustment, inspect and adjust the clutch release lever angle. •...
  • Page 91: Installation

    ENGINE RIGHT SIDE 5-7 Clutch Cable Installation • Run the clutch cable according to the Cable, Wire and Hose Routing section in the General Information chapter. • Adjust the clutch cable (see Free Play Adjustment). Lubrication and Inspection • Lubricate the clutch cable using the pressure cable luber in accordance with the Periodic Maintenance Chart.
  • Page 92: Clutch Cover

    5-8 ENGINE RIGHT SIDE Clutch Cover Clutch Cover Removal • Drain the engine oil (see Transmission Oil Change in the Engine Bottom End/Transmission chapter). • Remove the brake pedal (see Brake Pedal Removal in the Brake chapter). • Free the clutch inner cable at clutch lever side (see Clutch Cable Removal).
  • Page 93: Right Engine Cover

    Put a spanner wrench [A] on the shaft lever upper end. • Turn the shaft lever counterclockwise with the wrench, and separate the link lever [B] from the lever pin. KX85-A4 ∼/B4 ∼, KX100-D4 ∼ • Remove the KIPS cover from the cylinder right side. •...
  • Page 94: Cover Installation

    • Torque: Torque - Right Engine Cover Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb) KX85-A4 ∼/B4 ∼, KX100-D4 ∼ • Apply a non-permanent locking agent to the thread of lever assy mounting screw. • Install the spring to the lever shaft, put the one end of spring into the notch of the lever shaft, and install the collar, lever assy and washer with the specified torque.
  • Page 95: Advancer Disassembly

    Take off the advancer assembly [A]. Advancer Disassembly KX85-A3 ∼/B3 ∼, KX100-D3 ∼ The advancer assembly of the KX85-A3 ∼/B3 ∼ and KX100-D3 ∼ can be disassembled. • Hold the bearing puller [A] in a vise, and set the advancer assembly [B] with the gear upward on the bearing puller.
  • Page 96: Advancer Assembly

    Advancer Assembly KX85-A3 ∼ /B3 ∼, KX100-D3 ∼ • Press the gear [A] on the shaft so that the gear contacts the step on the shaft.
  • Page 97: Clutch

    ENGINE RIGHT SIDE 5-13 Clutch Removal • Remove the clutch cover. • Remove the magneto cover. • Unscrew the crankshaft sensor mounting screws and re- move the crankshaft sensor [B] from the stator. • Install the flywheel holder [A] on the magneto flywheel. NOTE ○...
  • Page 98: Installation Notes

    5-14 ENGINE RIGHT SIDE Clutch Installation Notes • Apply molybdenum disulfide grease to the outside of the sleeve. • Apply transmission oil to the inside of the clutch housing gear and Kickstarter driven gear. • Install the friction plates and steel plates, starting with a friction plate and alternating them.
  • Page 99: Friction And Steel Plate Warp Inspection

    ENGINE RIGHT SIDE 5-15 Clutch Friction and Steel Plate Warp Inspection • Place each friction plate or steel plate on a surface plate, and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C].
  • Page 100: Primary Gear

    5-16 ENGINE RIGHT SIDE Primary Gear ∼ ∼ ∼ Removal (KX85-A1 A5/B1 B5, KX100-D1 • Remove the right engine cover (see Right Engine Cover Removal). • Remove the circlip [A], then pull out the primary gear [B]. Special Tool - Outside Circlip Pliers: 57001-144 ∼...
  • Page 101 ENGINE RIGHT SIDE 5-17 Primary Gear • Using the gear holder [A], secure the clutch gear and the bottom of the primary gear; then, tighten the primary gear nut [B]. ○ Primary gear nut is left-hand threads. Torque - Primary Gear Nut: 49 N·m (5.0 kgf·m, 36 ft·lb) Special Tool - Gear Holder: 57001-1602 •...
  • Page 102: External Shift Mechanism

    5-18 ENGINE RIGHT SIDE External Shift Mechanism Removal • Remove the following. Brake Pedal (see Brakes chapter) Magneto Cover Shift Pedal Clutch (see Clutch Removal) • Pull out the shift shaft with the shift mechanism arm and arm spring. • Remove the gear set lever spring [A].
  • Page 103: Kickstarter

    ENGINE RIGHT SIDE 5-19 Kickstarter Removal • Remove the following parts. Right Engine Cover (see Right Engine Cover Removal) Clutch Housing Spring Guide [A] • Pull the end of the kick spring [B] out of the hole in the crankcase. •...
  • Page 105 ENGINE REMOVAL/INSTALLATION 6-1 Engine Removal/Installation Table of Contents Exploded View........................Engine Removal/Installation ....................Removal..........................Installation.........................
  • Page 106: Exploded View

    6-2 ENGINE REMOVAL/INSTALLATION Exploded View T1: 29 N·m (3.0 kgf·m, 22 ft·lb) T2: 69 N·m (7.0 kgf·m, 51 ft·lb)
  • Page 107: Removal

    ENGINE REMOVAL/INSTALLATION 6-3 Engine Removal/Installation Removal • The following parts may be removed with the engine in the frame. Clutch (see Engine Right Side chapter) Flywheel Magneto (see Electrical System chapter) • Remove the following. Engine Oil (drain, see Engine Bottom End/Transmission chapter) Coolant (drain, see Cooling System chapter) Seat (see Frame chapter)
  • Page 108: Installation

    6-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Move the engine forward and remove it from the vehicle right or left side. Installation • Engine installation is the reverse of removal. • Torque: Torque - Swingarm Pivot Shaft Nut: 69 N·m (7.0 kgf·m, 51 ft·lb) Engine Mounting Bracket Nuts: 29 N·m (3.0 kgf·m, 22 ft·lb)
  • Page 109 ENGINE BOTTOM END/TRANSMISSION 7-1 Engine Bottom End/Transmission Table of Contents Exploded View........................Specifications ......................... Transmission Oil........................Oil Level Inspection......................Engine Oil Change......................Crankcase ..........................Crankcase Splitting ......................Crankcase Disassembly ....................Crankcase Assembly ......................Crankshaft, Connecting Rod ....................7-10 Crankshaft Removal ......................7-10 Crankshaft Installation ......................
  • Page 110: Exploded View

    1. Water Pump Gear G: Apply grease 2. Primary Gear LG: Apply liquid gasket (Liquid Gasket, 3. KX85-A1 ∼ A5/B1 ∼ B5, KX100-D1 ∼ D5 TB1105B: 92104-002). T1: 29 N·m (3.0 kgf·m, 22 ft·lb) Lh: Left-hand threads T2: 8.8 N·m (0.90 kgf·m, 78 in·lb) O: Apply 2-stroke racing oil.
  • Page 111 Exploded View 1: KX85-A2 ∼/B2 ∼, KX100-D2 ∼ T1: 23 N·m (2.3 kgf·m, 16.5 ft·lb) 2: KX85-A1 ∼ A4/B1 ∼ B4, KX100-D1 ∼ D4 T2: 8.8 N·m (0.90 kgf·m, 78 in·lb) T3: 22 N·m (2.2 kgf·m, 16 ft·lb) G: Apply grease.
  • Page 112: Specifications

    Viscosity SAE10W-40 – – – – – – Oil Level In middle of level gauge 0.65 L (KX85-A1 ∼ A3/B1 ∼ B3, Capacity – – – KX100-D1 ∼ D3) 0.70 L (KX85-A4 ∼/B4 ∼, KX100-D4 ∼) Crankshaft, Connecting Rod 0.023 ∼ 0.035 mm Connecting Rod Big End Radial 0.08 mm...
  • Page 113: Transmission Oil

    ENGINE BOTTOM END/TRANSMISSION 7-5 Transmission Oil In order for the transmission and clutch to function prop- erly, always maintain the transmission oil at the proper level and change the oil periodically. WARNING Vehicle operation with insufficient, deteriorated, or contaminated transmission oil will cause acceler- ated wear and may result in engine or transmission seizure, accident, and injury.
  • Page 114 Fill the engine with a good quality motor oil specified in the table. • Check the oil level. Recommended Engine Oil KX85A1 ∼ A3/B1 ∼ B3, KX85-A4 ∼/B4 ∼, KX100-D1 ∼ D3 KX100-D4 ∼ Engine Oil: ← Grade API SG, SH, SJ, SL...
  • Page 115: Crankcase

    ENGINE BOTTOM END/TRANSMISSION 7-7 Crankcase Crankcase Splitting • The following parts may be removed with the engine in the frame. Clutch (see Engine Right Side chapter) Magneto Flywheel and Stator (see Electrical System chapter)) • Remove the engine (see the Engine Removal/Installation chapter).
  • Page 116: Crankcase Assembly

    7-8 ENGINE BOTTOM END/TRANSMISSION Crankcase Crankcase Assembly NOTICE Right and left crankcase halves are machined at the factory in the assembled state, so they must be re- placed together as a set. • Chip off the old gasket from the mating surfaces of the crankcase halves, and clean off the crankcase with a high flash-point solvent.
  • Page 117 ENGINE BOTTOM END/TRANSMISSION 7-9 Crankcase • The crankshaft jig must be installed between the flywheel opposite the connecting rod big end with the crankshaft at BDC. This is to protect flywheel alignment [A] Crankshaft [B] Connecting Rod [C] Crankshaft Jig: 57001-1174 •...
  • Page 118: Crankshaft, Connecting Rod

    7-10 ENGINE BOTTOM END/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Removal • See Crankcase Splitting. Crankshaft Installation • See crankcase Assembly. Crankshaft Disassembly Since assembly of the crankshaft demands exacting toler- ances, the disassembly of the crankshaft can only be done by a shop having the necessary tools and equipment. •...
  • Page 119: Connecting Rod Big End Radial Clearance Inspection

    ENGINE BOTTOM END/TRANSMISSION 7-11 Crankshaft, Connecting Rod Connecting Rod Big End Radial Clearance Inspection • Set the crankshaft in a flywheel alignment jig or on V blocks, and place a dial gauge against the connecting rod big end. • Push the connecting rod first towards the gauge and then in the opposite direction.
  • Page 120: Crankshaft Alignment Inspection

    7-12 ENGINE BOTTOM END/TRANSMISSION Crankshaft, Connecting Rod Crankshaft Alignment Inspection If the runout at either point exceeds the service limit, align the flywheels so that the runout falls within the service limit. • In the case of horizontal misalignment, which is the most common, strike the projecting rim of the flywheel with a plastic, soft lead, or brass hammer as indicated in the figure.
  • Page 121: Transmission

    Be careful not to install the gears backwards. ○ The 2nd drive gear shall be installed so that the circle of identification groove face to outward (KX85-A1 ∼ A4/B1 ∼ B4, KX100-D1 ∼D4). If the first gear on the output shaft is a new one, apply...
  • Page 122: Shift Fork Bending Inspection

    7-14 ENGINE BOTTOM END/TRANSMISSION Transmission KX85-A1/B1, KX100-D1 KX85-A2 ∼/B2 ∼, KX100-D2 ∼ Shift Fork Bending Inspection • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power.
  • Page 123: Shift Fork/Gear Groove Wear Installation

    ENGINE BOTTOM END/TRANSMISSION 7-15 Transmission Shift Fork/Gear Groove Wear Installation • Measure the thickness of the shift fork ears [A], and mea- sure the width of the shift fork grooves [B] in the transmis- sion gears. If the thickness of a shift fork finger is less than the service limit, the shift fork must be replaced.
  • Page 125 WHEELS/TIRES 8-1 Wheels/Tires Table of Contents Exploded View........................Specifications ......................... Wheels (Rims) ........................Front Wheel Removal ....................... Front Wheel Installation ....................Rear Wheel Removal......................Rear Wheel Installation..................... Wheels Inspection......................Spoke Inspection ......................Rim Inspection ........................Axle Inspection........................Tires............................Removal..........................Installation......................... 8-10 Air Pressure Inspection/Adjustment..................
  • Page 126: Exploded View

    8-2 WHEELS/TIRES Exploded View T1: 79 N·m (8.1 kgf·m, 58 ft·lb) T2: 1.5 ∼ 3.0 N·m (0.15 ∼ 0.31 kgf·m, 13 ∼ 27 in·lb) G: Apply grease. WL: Apply soap and water solution, or rubber lubricant.
  • Page 127: Specifications

    WHEELS/TIRES 8-3 Specifications Item Standard Service Limit Wheels Rim Runout (with tire installed): Axial/Radial TIR 1.0 mm (0.04 in.) or less TIR 2 mm (0.08 in.) Axle Runout/100 mm TIR 0.10 mm (0.004 in.) or less TIR 0.2 mm (0.008 in.) (3.94 in.): Tires Air Pressure Front and Rear...
  • Page 128 8-4 WHEELS/TIRES Specifications Item Standard Service Limit D1 ∼ D4 D5, D6F ∼ Rim Size: ← Front 19 × 1.40 ← Rear 16 × 1.85 (EU) Europe Model WARNING Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death.
  • Page 129: Wheels (Rims)

    WHEELS/TIRES 8-5 Wheels (Rims) Front Wheel Removal • Remove the following. Cotter Pin [A] Axle Nut [B] • Using the jack [A] and a stand [B], raise the front wheel off the ground. Special Tool - Jack: 57001-1238 • Pull out the axle to the right and drop the front wheel out of the forks.
  • Page 130: Rear Wheel Removal

    8-6 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal • Remove the following Axle Nut Cotter Pin [A] Rear Axle Nut [B] Caliper Mounting Bolts [C] • Using the jack [A] or a stand, raise the rear wheel off the ground. Special Tool - Jack: 57001-1238 •...
  • Page 131: Wheels Inspection

    WHEELS/TIRES 8-7 Wheels (Rims) • Check the rear brake. WARNING After servicing, it takes several applications of the brake pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake pedal is obtained by pumping the pedal until the pads are against the disc.
  • Page 132: Axle Inspection

    8-8 WHEELS/TIRES Wheels (Rims) Axle Inspection • Place the axle in V blocks that are 100 mm (3.94 in.) [A] apart, and set a dial gauge on the axle at a point halfway between the blocks. Turn the axle to measure the runout. The difference between the highest and lowest dial read- ings is the amount of runout.
  • Page 133: Tires

    WHEELS/TIRES 8-9 Tires Removal • Remove the following. Wheel (see Wheel Removal) Disc NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
  • Page 134: Installation

    8-10 WHEELS/TIRES Tires Installation • Inspect the rim and tire, and replace them if necessary. • Install the tube. • Apply a soap and water solution, or rubber lubricant to the rim flange and tire beads. • Position the tire on the rim so that the valve [A] is at the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire.
  • Page 135: Inspection

    WHEELS/TIRES 8-11 Tires Inspection As the tire tread wears down, the tire becomes more sus- ceptible the puncture and failure. • Remove any imbedded stones or other foreign particles from the tread. • Visually inspect the tire for cracks and cuts, replacing the tire in case of bad damage.
  • Page 136: Hub Bearing (Wheel Bearings)

    8-12 WHEELS/TIRES Hub Bearing (Wheel Bearings) Removal • Remove the following. Wheel (see Wheel Removal) Oil Seals and Circlips • Use the bearing remover to remove the hub bearings [A]. Special Tool - Bearing Remover Shaft, 9: 57001-1265 [B] Bearing Remover Head, 10 ×...
  • Page 137 FINAL DRIVE 9-1 Final Drive Table of Contents Exploded View........................Specifications ......................... Drive Chain..........................Slack Adjustment ......................Wheel Alignment Adjustment.................... Wear Inspection ........................ Lubrication ........................Removal..........................Installation......................... Sprockets..........................Engine Sprocket Removal ....................Engine Sprocket Installation .................... Rear Sprocket Removal....................Rear Sprocket Installation....................Sprocket Wear ........................
  • Page 138: Exploded View

    9-2 FINAL DRIVE Exploded View 1. KX85-A1 ∼ A4/B1 ∼ B4, KX100-D1 ∼ D4 2. Chain Adjuster Locknuts T1: 79 N·m (8.0 kgf·m, 58 ft·lb) T2: 32 N·m (3.3 kgf·m, 24 ft·lb) T3: 9.8 N·m (1.0 kgf·m, 87 in·lb) G: Apply grease HO: Apply heavy oil.
  • Page 139: Specifications

    FINAL DRIVE 9-3 Specifications Item Standard Service Limit Drive Chain Make and Type Daido, DID 420DS2, Joint Endless KX85A 120 links – – – KX85B, KX100 D 124 links – – – 54 ∼ 64 mm (2.13 ∼ 2.52 in.) Chain Slack –...
  • Page 140: Slack Adjustment

    9-4 FINAL DRIVE Drive Chain Slack Adjustment • Set the motorcycle up on its side stand. • Check to see that the notches [A] on the alignment indi- cators [B] on both sides are in the same relative position [C]. If they are not, adjust the chain slack and align them.
  • Page 141: Wheel Alignment Adjustment

    FINAL DRIVE 9-5 Drive Chain NOTE ○ In wet and muddy conditions, mud sticks to the chain and sprockets resulting in an overly tight chain, and the chain may break. • Check the rear brake (see Brakes chapter). WARNING After servicing, it takes several applications of the brake pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death.
  • Page 142: Lubrication

    9-6 FINAL DRIVE Drive Chain If any measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced. WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control.
  • Page 143: Sprockets

    FINAL DRIVE 9-7 Sprockets Engine Sprocket Removal • Remove the following parts. Magneto Cover Drive Chain [A] (free of engine sprocket) • Remove the engine sprocket circlip [B], and pull off the engine sprocket [C]. Special Tool - Outside Circlip Pliers: 57001-144 Engine Sprocket Installation •...
  • Page 144: Rear Sprocket Warp

    9-8 FINAL DRIVE Sprockets Rear Sprocket Warp • Using the jack or a stand, raise the rear wheel off the ground (see Wheels/Tires chapter). Special Tool - Jack: 57001-1238 • Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown.
  • Page 145 BRAKES 10-1 Brakes Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Disc Brake Information ......................10-5 Brake Lever and Pedal ......................10-6 Brake Lever Play Adjustment.................... 10-6 Pedal Position Adjustment ....................10-6 Pedal Removal........................10-7 Pedal Installation Notes ....................10-7 Calipers ..........................
  • Page 146: Exploded View

    10-2 BRAKES Exploded View 1. KX85A9F ∼/KX85B9F ∼, KX100D9F T1: 5.9 N·m (0.60 kgf·m, 52 in·lb) T2: 1.5 N·m (0.15 kgf·m, 13 in·lb) T3: 7.8 N·m (0.80 kgf·m, 69 in·lb) T4: 8.8 N·m (0.90 kgf·m, 78 in·lb) T5: 9.8 N·m (1.0 kgf·m, 87 in·lb) T6: 25 N·m (2.5 kgf·m, 18 ft·lb) T7: 4.9 N·m (0.50 kgf·m, 43 in·lb) L: Apply a non-permanent locking agent.
  • Page 147 BRAKES 10-3 Exploded View T1: 5.9 N·m (0.60 kgf·m, 52 in·lb) T2: 25 N·m (2.5 kgf·m, 18 ft·lb) T3: 18 N·m (1.8 kgf·m, 13 ft·lb) T4: 7.8 N·m (0.8 kgf·m, 69 in·lb) T5: 9.8 N·m (1.0 kgf·m, 87 in·lb) G: Apply grease. L: Apply a non-permanent locking agent.
  • Page 148: Specifications

    10-4 BRAKES Specifications Item Standard Service Limit Brake Adjustment Brake Lever Free Play Adjustable (to suit rider) – – – Brake Pads Pad Lining Thickness: Front 4.0 mm (0.16 in.) 1 mm (0.04 in.) Rear 4.0 mm (0.16 in.) 1 mm (0.04 in.) Brake Disc Disc Thickness: 2.85 ∼...
  • Page 149: Disc Brake Information

    BRAKES 10-5 Disc Brake Information WARNING When working with the disc brake, observe the pre- cautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3.
  • Page 150: Brake Lever And Pedal

    10-6 BRAKES Brake Lever and Pedal Brake Lever Play Adjustment • Adjust the front brake lever [A] to suit you. • Loosen the adjuster locknut [C] and turn the adjuster [D] to either side. • After adjustment, tighten the locknut to the specified torque.
  • Page 151: Pedal Removal

    BRAKES 10-7 Brake Lever and Pedal Pedal Removal • Remove the following. Brake Pedal Return Spring [A] Cotter Pin Joint Pin [B] • Remove the brake pedal bolt [C] and remove the brake pedal [D]. Pedal Installation Notes • Grease the brake pedal hole. •...
  • Page 152: Calipers

    10-8 BRAKES Calipers Caliper Removal • Loosen the banjo bolt [A] so as not to spill brake fluid. • Remove the caliper mounting bolts [B]. • Remove the caliper [C]. • Remove the banjo bolt and take off the brake hose from the caliper (see Brake Hose Removal/Installation).
  • Page 153: Assembly Notes

    BRAKES 10-9 Calipers WARNING The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston. • Remove the dust seal and fluid seal. • Remove the bleed valve and rubber cap. Assembly Notes •...
  • Page 154: Caliper Holder Shaft Wear Inspection

    10-10 BRAKES Calipers Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and con- stant drag on the disc will raise brake and brake fluid tem- perature.
  • Page 155: Brake Pads

    BRAKES 10-11 Brake Pads Removal • When removing the rear brake pads, take off the caliper guard and loosen the pad bolts [A]. • Remove the caliper [B] with the hose installed (see Caliper Removal). • Remove the pad bolt (Rear Caliper). •...
  • Page 156: Brake Pad Wear Inspection

    10-12 BRAKES Brake Pads Brake Pad Wear Inspection • Check the lining thickness [A] of the pads in each caliper. If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set. Pad Lining Thickness (front and rear) Standard: 4.0 mm (0.16 in.)
  • Page 157: Master Cylinder

    BRAKES 10-13 Master Cylinder Front Master Cylinder Removal • Drain the front brake fluid (see Brake Fluid Change). • Remove the following. Brake Hose Banjo Bolt [A] Master Cylinder Clamp Bolts • Remove the front master cylinder [B] Front Master Cylinder Installation •...
  • Page 158: Inspection And Adjustment After Installation

    10-14 BRAKES Master Cylinder Inspection and Adjustment after Installation • Fill the brake line with the brake fluid (see Brake Fluid Change). • Check and adjust the following items after installation. Brake Pedal Position Brake Line Air Bleed Brake Drag Braking Power Brake Fluid Leakage WARNING...
  • Page 159: Rear Master Cylinder Disassembly

    BRAKES 10-15 Master Cylinder Rear Master Cylinder Disassembly NOTE ○ Do not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal posi- tion adjustment. • Remove the following. Rear Master Cylinder (see Rear Master Cylinder Re- moval) Dust Cover on Push Rod Retainer (use the inside circlip pliers: 57001-143)
  • Page 160: Inspection (Visually)

    10-16 BRAKES Master Cylinder Inspection (Visually) • Disassemble the front and rear master cylinder. • Check that there are no scratches, wear, rust or pitting on the following parts. Inside of the Master Cylinder Outside of the Piston Primary Cup Secondary Cup Dust Cover Return Spring...
  • Page 161: Brake Disk

    BRAKES 10-17 Brake Disk Brake Disc Removal • Remove: Front Wheel (see Wheels/Tires chapter) Rear Wheel (see Wheels/Tires chapter) • Remove the brake discs from the wheels. Brake Disc Installation • Install the disc on the wheels so that the mark side of it faces out.
  • Page 162: Brake Fluid

    10-18 BRAKES Brake Fluid Fluid Level Inspection In accordance with the Periodic Maintenance Chart, in- spect the brake fluid level in the front [A] and rear [C] brake fluid reservoirs. • Check the brake fluid level in the reservoir. NOTE ○...
  • Page 163: Bleeding The Brake Line

    BRAKES 10-19 Brake Fluid • Level the brake fluid reservoir. • Remove the reservoir cap and the rubber cap [B] on the bleed valve [A]. • Attach a clear plastic hose [C] to the bleed valve on the caliper, and run the other end of the hose into a container. •...
  • Page 164 10-20 BRAKES Brake Fluid NOTE ○ The procedure to bleed the front brake line is as follows. Bleeding the rear brake line is the same as for the front brake. • Bleed the air whenever brake parts are replaced or re- assembled.
  • Page 165: Brake Hose

    BRAKES 10-21 Brake Hose Removal/Installation • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. • When removing the brake hose, temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum.
  • Page 167 SUSPENSION 11-1 Suspension Table of Contents Exploded View........11-2 Disassembly......... 11-19 Specifications ........11-4 Assembly ........11-20 Front Fork .......... 11-5 Spring Tension ......11-21 Air Pressure Adjustment ....11-5 Scrapping........11-21 Compression Damping Swingarm........... 11-22 Adjustment ........ 11-5 Removal........11-22 Fork Oil Level Adjustment (each Installation........
  • Page 168: Exploded View

    11-2 SUSPENSION Exploded View 1: KX85-A1 ∼ A2/B1 ∼ B2, KX100-D1 ∼ D2 T1: 27 N·m (2.8 kgf·m, 20 ft·lb) 2: KX85-A3 ∼/B3 ∼, KX100-D3 ∼ T2: 20 N·m (2.0 kgf·m, 15 ft·lb) T3: 54 N·m (5.5 kgf·m, 40 ft·lb) T4: 15 N·m (1.5 kgf·m, 11 ft·lb)
  • Page 169 SUSPENSION 11-3 Exploded View T1: 83 N·m (8.5 kgf·m, 61 ft·lb) T2: 59 N·m (6.0 kgf·m, 44 ft·lb) T3: 39 N·m (4.0 kgf·m, 29 ft·lb) T4: 69 N·m (7.0 kgf·m, 51 ft·lb) G: Apply grease. L: Apply a non-permanent locking agent M: Apply Molybdenum disulfide grease.
  • Page 170: Specifications

    11-4 SUSPENSION Specifications Item Standard Service Limit Front Fork Air Pressure Atmospheric pressure – – – Compression Damping Adjustment Refer to 11-5 – – – – – – Oil Type KHL15-10 (KAYABA01) or equivalent Oil Capacity: KX85A 315 ±4 mL (10.7 ±0.14 US oz) –...
  • Page 171: Air Pressure Adjustment

    SUSPENSION 11-5 Front Fork Air Pressure Adjustment ○ The air pressure in the fork legs is atmospheric pressure. The air pressure in the fork legs increases as the fork heats up, so the fork action will get stiffer as the vehicle operation progresses.
  • Page 172 11-6 SUSPENSION Front Fork • Use wretches on the rod nut and the top plug [A] to loosen the rod nut. • Remove the top plug from the push rod. • Remove the fork spring holder (special tool). • Lift the fork spring [B] and its top spring seat [C] out of the inner tube.
  • Page 173 SUSPENSION 11-7 Front Fork • Screw the fork piston rod puller [A] onto the end of the rod. Special Tool - Fork Piston Rod Puller, M10 × 1.0: 57001 -1298 • Purge the air from the fork cylinder by gently moving the rod puller [A] up and down five times.
  • Page 174: Fork Clamp Position Adjustment

    11-8 SUSPENSION Front Fork Fork Clamp Position Adjustment Fork clamp position greatly affects steering qualities. Fork tube height is the amount of the inner tube projecting above the steering stem head. When the fork tube height is smaller, the front end becomes lighter due to change in weight bias.
  • Page 175: Front Fork Removal

    SUSPENSION 11-9 Front Fork ○ With the fork fully compressed, and held upright, measure the distance [D] from the top of the oil (see Front Oil Level Adjustment). Special Tool - Fork Oil Level Gauge: 57001-1290 [A] If the oil is above or below the specified level, remove or add oil and recheck the oil level.
  • Page 176: Disassembly (Each Fork Leg)

    11-10 SUSPENSION Front Fork NOTE ○ Tighten the two clamp bolts alternately two times to en- sure even tightening torque. • Check the front brake for good braking power, no brake drag, and no fluid leakage after installing the front fork. Disassembly (each fork leg) •...
  • Page 177: Assembly (Each Fork Leg)

    SUSPENSION 11-11 Front Fork <Inner Tube Removal> • Separate the inner tube [A] from the outer tube [B] as follows: ○ Slide up the spring band [C]. ○ Slide up the dust seal [D]. ○ Remove the retaining ring [B] from the outer tube [A]. ○...
  • Page 178 11-12 SUSPENSION Front Fork • Install the following onto the inner tube. Washer [A] Outer Tube Guide Bush [B] Inner Tube Guide Bush [C] • When installing the outer tube guide bush [A] into the outer tube, put the washer on the outer tube guide bush, and tap the washer with the fork oil seal driver [B] until it stops.
  • Page 179: Spring Tension

    SUSPENSION 11-13 Front Fork • Screw the push rod nut until it touched the spring guide. • Pour in the type and amount of fork oil specified and adjust the oil level (see Fork Oil Level Adjustment). • Screw the fork push rod puller [A] onto the end of the push rod.
  • Page 180: Rear Shock Absorber

    11-14 SUSPENSION Rear Shock Absorber To suit to various riding conditions, the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one. Also the damping force can be adjusted easily so changing oil viscosity unnecessary. Compression Damping Force Adjustment •...
  • Page 181: Removal

    SUSPENSION 11-15 Rear Shock Absorber • Using the steering stem nut wrenches [A], loosen the lock- nut [B] and turn the adjusting nut [C] as required. Special Tool - Steering Stem Nut Wrench: 57001-1100 • Turning the adjusting nut [A] downward makes the spring action harder and upward softer.
  • Page 182: Installation

    11-16 SUSPENSION Rear Shock Absorber NOTICE When pulling out the mounting bolts, lift the swingarm slightly. Forcing or tapping on a bolt could damage the bolt, sleeve, and bearing • Remove the rear shock absorber. Installation • Installation is the reverse of removal. •...
  • Page 183: Oil Draining

    SUSPENSION 11-17 Rear Shock Absorber Oil Draining The oil should be changed in the rear shock absorber at least once per racing season. The frequency for best per- formance must be based upon riding conditions and rider ability. • Remove the following. Rear Shock (see Rear Shock Absorber Removal) Rear Shock Spring (see Spring Replacement) •...
  • Page 184: Oil Filling

    11-18 SUSPENSION Rear Shock Absorber Oil Filling • Check the O-ring on the air bleeder bolt, and replace it if necessary. • Install the air bleeder bolt. • Pour KHV10-K2C (KAYABA) (SAE 5W or Bel-Ray SE2 #40) oil into the rear shock body to 31 ∼ 35 mm (1.22 ∼ 1.38 in.) (from the shock body lower end.
  • Page 185: Disassembly

    SUSPENSION 11-19 Rear Shock Absorber If oil comes out of the air bleeder bolt hole, let it overflow until it stops. If oil does not come out of the air bleeder bolt hole, add the specified oil into the air bleeder bolt hole until it overflows (that is, until all the remaining air is forced out).
  • Page 186: Assembly

    11-20 SUSPENSION Rear Shock Absorber • Install a steel tire valve cap [A] on the gas reservoir valve, and pull the gas reservoir cap out of the gas reservoir using pliers. ○ The bladder [B] comes out with the gas reservoir cap. Assembly •...
  • Page 187: Spring Tension

    SUSPENSION 11-21 Rear Shock Absorber • Pull up the gas reservoir cap [A] against the circlip. The end [B] of the gas reservoir cap must be 1 mm (0.039 in.) lower than the end [C] of the gas reservoir. WARNING Pressurized nitrogen gas can explode out of the shock reservoir cap if the circlip is not properly in- stalled, allowing oil and internal parts to burst out of...
  • Page 188: Swingarm

    11-22 SUSPENSION Swingarm Removal • Squeeze the brake lever slowly and hold it with a band. • Remove the following. Rear Brake Hose Straps Rear Brake Caliper (see Brake chapter) Tie Rod Rear Bolt [A] (see Tie-Rod Removal) Swingarm Pivot Shaft Nut [B] Rear Wheel (see Wheels/Tires chapter) •...
  • Page 189: Swingarm Bearing Installation

    SUSPENSION 11-23 Swingarm SwingArm Bearing Installation • Replace the needle bearings, dust seals and oil seals with new ones. • Apply plenty of molibdenum disulfide grease to the dust seals, oil seals and needle bearings. NOTE ○ Install the needle bearings so that the manufacturer’s marks face out.
  • Page 190: Tie-Rod, Rocker Arm

    11-24 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal • Raise the rear wheel off the ground (see Wheel/Tires chapter). • Squeeze the brake lever slowly and hold it with a band. • Remove the following. Front and Rear Tie-Rod Bolts [A] NOTICE When pulling out the tie-rod bolts, lift the swingarm or the rocker arm slightly.
  • Page 191: Rocker Arm/Tie-Rod Bearing Removal

    SUSPENSION 11-25 Tie-Rod, Rocker Arm Rocker Arm/Tie-Rod Bearing Removal • Remove the rocker arm for the rocker arm bearing re- moval (see Rocker Arm/Tie-Rod Bearing Removal). • Remove the swingarm for the tie-rod bearing removal (see Rocker Arm/Tie-Rod Bearing Removal). •...
  • Page 193 STEERING 12-1 Steering Table of Contents Exploded View........................12-2 Specifications ......................... 12-3 Handlebar ..........................12-4 Installation......................... 12-4 Clutch Lever Installation....................12-4 Steering ..........................12-5 Adjustment ........................12-5 Steering Stem......................... 12-6 Removal..........................12-6 Installation......................... 12-6 Bearing Seal Deterioration, Damage Inspection............... 12-6 Steering Stem Warp Inspection ..................
  • Page 194: Exploded View

    12-2 STEERING Exploded View T1: 25 N·m (2.5 kgf·m, 18 ft·lb) T2: 64 N·m (6.5 kgf·m, 47 ft·lb) T3: 20 N·m (2.0 kgf·m, 15 ft·lb) T4: Hand tight or 4.9 N·m (0.49 kgf·m, 43 in·lb) AD: Apply adhesive. G: Apply grease. O: Apply oil.
  • Page 195: Specifications

    STEERING 12-3 Specifications Special Tools - Bearing Driver, 32: 57001-382 Head Pipe Outer Race Press Shaft: 57001-1075 Steering Stem Bearing Driver Adapter: 57001-1092 Steering Stem Nut Wrench: 57001-1100 Head Pipe Outer Race Driver, 46.5: 57001-1106 Head Pipe Outer Race Remover ID > 37 mm: 57001-1107 Jack: 57001-1238...
  • Page 196: Handlebar

    12-4 STEERING Handlebar Installation • Install the handlebar holders so that the arrow [A] on the holder points to the front. • Align the punch mark [D] on the handlebar to the mating surface of each clamps of handlebar, front master cylin- der.
  • Page 197: Adjustment

    STEERING 12-5 Steering Adjustment • Check the steering. ○ Lift the front wheel off the ground using a stand and the jack. Special Tool - Jack: 57001-1238 ○ With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the rib hits the stop.
  • Page 198: Steering Stem

    12-6 STEERING Steering Stem Removal • Remove the following parts. Steering Stem Head Nut [A] Front Fender Front Fork Legs (see Suspension chapter) Handlebar Stem Head Upper Steering Stem Bearing [C] • Push up on the steering stem [D], and remove the stem nut [B] using the stem nut wrench, then remove the steer- ing stem base.
  • Page 199: Steering Stem Warp Inspection

    STEERING 12-7 Steering Stem Steering Stem Warp Inspection • Whenever the steering stem is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness. If the steering stem shaft [A] is bent, replace the steering stem.
  • Page 200: Steering Stem Bearing

    12-8 STEERING Steering Stem Bearing Removal • Remove the steering stem (see Steering Stem Removal). • To remove the outer races pressed into the head pipe, install the outer race remover as shown below. Special Tool - Head Pipe Outer Race Remover ID > 37 mm: 57001-1107 [A] •...
  • Page 201: Lubrication

    STEERING 12-9 Steering Stem Bearing ○ Check that there is no play and the steering stem turns smoothly without the rattle. If not, the steering stem bearing may be damaged. ○ Again back out the stem nut a fraction of turn until it turns lightly.
  • Page 203 FRAME 13-1 Frame Table of Contents Exploded View........................13-2 Seat ............................13-3 Seat Removal ........................13-3 Seat Installation ........................ 13-3 Side Covers ..........................13-4 Side Cover Removal ......................13-4...
  • Page 204: Exploded View

    13-2 FRAME Exploded View 1. Rear Frame Pipe. 2. Front Fender Mounting Bolts T1: 34 N·m (3.5 kgf·m, 25 ft·lb) T2: 5.9 N·m (0.60 kgf·m, 52 in·lb) O: Apply Oil.
  • Page 205: Seat

    FRAME 13-3 Seat Seat Removal • Remove the seat bolts [A]. • Move back [B] and swing open the seat [C], and then remove it. Seat Installation • Slip the hooks [A] of the seat under the washer [B] on the fuel tank and the brace [C].
  • Page 206: Side Covers

    13-4 FRAME Side Covers Side Cover Removal • Remove: Seat Bolts [A] Side Cover Bolts [B] Side Covers...
  • Page 207 ELECTRICAL SYSTEM 14-1 Electrical System Table of Contents Exploded View........................14-2 Wiring Diagram........................14-3 Specifications ......................... 14-4 Precautions and Safety Instructions ..................14-5 Safety Instructions ....................... 14-5 Electrical Wiring........................14-6 Inspection.......................... 14-6 Ignition Timing ........................14-7 Adjustment ........................14-7 Flywheel Magneto ........................14-8 Removal..........................
  • Page 208: Exploded View

    T4: 5.2 N·m (0.53 kgf·m, 43 in·lb) 5. Magneto Stator T5: 8.8 N·m (0.90 kgf·m, 78 in·lb) 6. Crankshaft Sensor SS: Apply silicone sealant (Liquid Gasket, 7. Magneto Flywheel TB1211: 56019-120). 8. KX85-A1 ∼ A5/B1 ∼ B5, KX100-D1 ∼ D5...
  • Page 209: Wiring Diagram

    ELECTRICAL SYSTEM 14-3 Wiring Diagram KX85-A1 ∼ A5/B1 ∼ B5, KX100-D1 ∼ D5 KX85-A6F ∼/B6F ∼, KX100-D6F ∼...
  • Page 210: Specifications

    14-4 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Magneto Flywheel Magneto Output Voltage 16 V or more – – – Ignition System Ignition Timing 12° BTDC @12 000 r/min (rpm) (KX85A1 – – – ∼ A5/B1 ∼ B5) 12° BTDC @12 040 r/min (rpm) (KX85A6F ∼/B6F ∼...
  • Page 211: Precautions And Safety Instructions

    ELECTRICAL SYSTEM 14-5 Precautions and Safety Instructions There are numbers of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.
  • Page 212: Electrical Wiring

    14-6 ELECTRICAL SYSTEM Electrical Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it.
  • Page 213: Ignition Timing

    ELECTRICAL SYSTEM 14-7 Ignition Timing Adjustment • Remove the magneto cover. • Check to see if the middle mark [A] of the three-marks on the magneto stator is aligned with the mark [B] on the crankcase. If the marks are not aligned, loosen the magneto stator mounting screws [C] and turn the magneto stator [D].
  • Page 214: Flywheel Magneto

    14-8 ELECTRICAL SYSTEM Flywheel Magneto Removal • Remove: Magneto Cover • Hold the flywheel steady with the flywheel & pully holder [A] and remove the flywheel nut [B]. Special Tool - Flywheel & Pully Holder: 57001-1605 • Remove the flywheel holder. •...
  • Page 215: Inspection

    ELECTRICAL SYSTEM 14-9 Flywheel Magneto • Set the stator wiring grommet [A] securely in the notch in the left crankcase half, and route the wires [B] according to the Cable, Wire and Hose Routing section in the Gen- eral Information chapter. •...
  • Page 216 14-10 ELECTRICAL SYSTEM Flywheel Magneto Magneto stator coil check • Check the magneto stator coil resistance as follows. ○ Disconnect the magneto lead connector [A]. ○ Connect the hand tester [B] as shown in the diagram. Special Tool - Hand Tester: 57001-1394 Magneto Stator Coil Resistance Connections Tester Range...
  • Page 217: Ignition System

    ELECTRICAL SYSTEM 14-11 Ignition System...
  • Page 218: Crankshaft Sensor Installation

    14-12 ELECTRICAL SYSTEM Ignition System WARNING The ignition system produces extremely high volt- age. Do not touch the spark plug, ignition coil or ig- nition coil lead while the engine is running, or you could receive a severe electrical shock. Crankshaft Sensor Installation •...
  • Page 219: Crankshaft Sensor Peak Voltage Inspection

    ELECTRICAL SYSTEM 14-13 Ignition System Crankshaft Sensor Peak Voltage Inspection • Disconnect the magneto lead connector [C]. • Set the hand tester [B] to the × 25 V DC range, and con- nect it the Peak voltage adapter [A] as shown in the dia- gram.
  • Page 220 14-14 ELECTRICAL SYSTEM Ignition System KX85A6F ∼/B6F ∼, KX100D6F ∼ Ignition Coil Arcing Distance Standard: 6 mm (0.24 in.) or more • To determine which part is defective, measure the arcing distance again with the spark plug cap removed from the ignition coil lead.
  • Page 221: Spark Plug Cleaning And Inspection

    ELECTRICAL SYSTEM 14-15 Ignition System KX85A6F ∼/B6F ∼, KX100D6F ∼ [C] Spark Plug Cleaning and Inspection • Remove the spark plug, and visually inspect it. • Clean the spark plug, preferably in a sandblasting device, and then clean off any abrasive particles. The plug may also be cleaned using a high flash-point solvent and a wire brush or other suitable tool.
  • Page 222: Engine Stop Button Electric Current Inspection

    14-16 ELECTRICAL SYSTEM Ignition System • Install the peak voltage Adapter [A] into the Hand Tester [B]. • Connect the adapter to the ignition coil primary lead ter- minal and the engine ground with the primary lead con- nected. CDI Unit [C] New Spark Plug [D] Ignition Coil [E] Special Tool - Hand Tester: 57001-1394...
  • Page 223 ELECTRICAL SYSTEM 14-17 Ignition System...
  • Page 225 APPENDIX 15-1 Appendix Table of Contents Troubleshooting Guide ......................15-2 General Lubrication ........................ 15-6 Lubrication (Periodic Maintenance) .................. 15-6 Bolt, Nut, and Fastener Tightness ..................15-7 Tightness Inspection ......................15-7 Unit Conversion Table ......................15-8...
  • Page 226: Troubleshooting Guide

    15-2 APPENDIX Troubleshooting Guide NOTE Cylinder head warped ○ This is not an exhaustive list, giving every Cylinder base gasket damaged possible cause for each problem listed. It Read valve damaged Cylinder nut loose is meant simply as a rough guide to assist the troubleshooting for some of the more Poor Running at Low Speed: common difficulties.
  • Page 227 APPENDIX 15-3 Troubleshooting Guide Poor Running or No Power at High Overheating Speed: Transmission oil level too high Firing incorrect: Transmission oil viscosity too high Crankshaft bearing worn or damaged Spark plug dirty, damaged, or maladjusted Spark plug cap or high tension wiring dam- KIPS ports stuck closed: aged KIPS ports stuck closed...
  • Page 228 15-4 APPENDIX Troubleshooting Guide Clutch spring broken or weak Piston seizure or damage Clutch release mechanism trouble Cylinder head gasket leaking Clutch hub or housing unevenly worn Exhaust pipe leaking at cylinder head con- Clutch not disengaging properly: nection Clutch lever play excessive Crankshaft runout excessive Clutch plate warped or too rough Engine mounts loose...
  • Page 229 APPENDIX 15-5 Troubleshooting Guide Fuel level too high Steering stem bent Front fork leg bent Handling and/or Stability Right/left front fork oil level uneven Unsatisfactory: Shock absorption unsatisfactory: (Too hard) Handlebar hard to turn: Front fork oil excessive Control Cable routing incorrect Front fork oil viscosity too high Wiring routing incorrect Front fork leg bent...
  • Page 230: General Lubrication

    15-6 APPENDIX General Lubrication Lubrication (Periodic Maintenance) • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubri-...
  • Page 231: Bolt, Nut, And Fastener Tightness

    APPENDIX 15-7 Bolt, Nut, and Fastener Tightness Bolt, Nut, and Fastener Tightness Tightness Inspection • Check the tightness of bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○...
  • Page 232: Unit Conversion Table

    15-8 APPENDIX Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 milli × 0.001 Units of Torque: µ micro ×...
  • Page 233 MODEL APPLICATION Year Model Beginning Frame No. Year Model Beginning Frame No. □ □ JKBKXFAC 1A000001 or JKBKXFAC 6A031001 or 2001 KX85-A1 2006 KX85A6F JKBKX085AAA000001 JKBKX085AAA031001 □ □ JKVKXFBC 1A000001 or JKBKXFBC 6A015001 or 2001 KX85-B1 2006 KX85B6F JKBKX085BBA000001 JKBKX085BBA015001 □...

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