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3 - Vermijs Motorsport

1. GENERAL INFORMATION 1 9 General Specifications Items KX85 A1 A5 A6F AAF KX85 B1 B5 B6F BAF 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 x 1 40 19 x 1 40 Rear 14 x 1 60 16 x 1 85 Front Suspension Type Telescopic fork Wheel Travel 275 mm 10 8 in Rear Suspension Type Swing arm Uni trak Wheel Travel 275 mm 10 8 in Brake Type Front and Rear Single disc Effective Disc Diameter Front 202 mm 8 0 in Rear 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 Items KX100 D1 D5 D6F D9F 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 Dry Weight KX100 D1 D8F 68 kg 150 lb Curb Mass KX100D9F 71 kg 157 Ib Front 35 kg 77 lb Rear 36 kg 79 Ib Fuel Tank Capaciry 5 5 L 1 5 US qal 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 2 stroke
2. Service Fuel Level Adjustment A 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 this includes any appliance with a pilot light e Remove the carburetor see Carburetor Removal e Remove the float bowl e Drive out the pivot pin A and remove the float B e Bend the tang A on the float arm very slightly to change the float height Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level e Install the float 6606019251 e Measure the float height tilting the carburetor so that the tang on the float just touches the needle rod in the float valve A Float Bowl Mating Surface B Needle Rod C Float D Float Height E Float Valve Float Height Standard 19 1 mm 0 75 0 04 in NOTE ODo not push the needle rod in during the float height measurement e Assemble the carburetor and recheck the fuel level Fuel System Clean A 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 this includes any appliance with a pilot light 2 10 FUEL SYSTEM Carburetor e Place a suitable container bene
3. Crankshaft Sensor Air Gap 0 5 0 1 mm 0 020 0 004 in lf the gap is incorrect reinstall the crankshaft sensor so that the gap has correct clearance Install the magneto cover Torque Magneto Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Inspection e There are three types of magneto problems short open wire burned out or loss in flywheel magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in flywheel magnetism which may be caused by dropping or hitting the flywheel or just by aging will result in low output Inspect the stator coils see Ignition System or replace the flywheel if the stator coils are good Magneto output voltage check e To check the magneto output voltage do the following procedures OConnect the hand tester A and magneto lead adapter B as shown in the diagram OStart the engine ORun it at the rpm given in the table ONote the voltage readings CDI unit C Magneto D Special Tool Lead Wire Magneto Lead Adapter 57001 1469 Hand Tester 57001 1394 Magneto Output Voltage Reading Tester Range Tester to Tester to 4 000 rpm X250 V DC BK W BK R x If the output voltage shows the value in the table the mag neto operates properly x If the output voltage shows a much lower reading than that given in the table indicates that the magneto is defective E ex _ BK R IO
4. 1 03 1 05 mm 0 0406 0 0413 in 1 01 1 03 mm 0 0398 0 0406 in 0 97 0 99 mm 0 0382 0 0390 in 0 30 0 50 mm 0 0118 0 0197 in 48 60 mm 1 91 in 52 60 mm 2 07 in 48 29 mm 1 90 in 48 29 mm 1 90 in 52 29 mm 2 06 in 0 16 mm 0 0063 in 0 18 mm 0 0071 in 0 16 mm 0 0063 in 1 11 mm 0 0437 in 1 13 mm 0 0445 in 1 11 mm 0 0437 in 0 90 mm 0 0354 in 0 80 mm 0 0315 in And less than 0 01 mm difference between any two measurements Or more than 0 05 mm difference between any two measurements Special Tools Compression Gauge 57001 221 Piston Pin Puller Assembly 57001 910 Compression Gauge Adapter M14 x 1 25 57001 1159 4 4 ENGINE TOP END Cylinder Head Compression Pressure Measurement e Start the engine e 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 e Stop the engine e Move the fuel tank backward with the hose left installed see Fuel System chapter e Remove the spark plug and screw a compression gauge firmly into the spark plug hole Special Tools Compression Gauge 57001 221 A Compression Gauge Adapter M14 x 1 25 57001 1159 B e With the throttle fully open turn the engine over sharply with the kickstarter several times until the compression gauge stops riding the compression is the highest read ing obtain
5. OThe 2nd drive gear shall be installed so that the circle of identification groove face to outward KX85 A1 A4 B1 B4 KX100 D1 D4 lf the first gear on the output shaft is a new one apply molybdenum disulfide grease to the internal diameter 6104008BS1i 7 14 ENGINE BOTTOM END TRANSMISSION Transmission KX85 A1 B1 KX100 D1 Drive Shaft 16mm 2ND 5TH 3RD 4TH 6TH 1ST Output Shaft 6113181Bw2 Drive Shaft L 2ND 5TH 3RD 4TH 6TH 1ST Output Shaft 6113183BW2 Shift Fork Bending Inspection e 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 A 90 O 6113014551 ENGINE BOTTOM END TRANSMISSION 7 15 Transmission Shift Fork Gear Groove Wear Installation e 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 Shift Fork Finger Thickness Standard 3 9 4 0 mm 0 154 0 157 in Service Limit 3 8 mm 0 150 in lf a gear shift fork groove is worn over the service limit the gear must be replaced Gear Shift Fork Groove Width Standard 4 05 4 15 mm 0 159 0 163 in Service Limit 4
6. ll HO 7 6P100624s1 14 10 ELECTRICAL SYSTEM Flywheel Magneto Magneto stator coil check e Check the magneto stator coil resistance as follows ODisconnect the magneto lead connector A OConnect the hand tester B as shown in the diagram Special Tool Hand Tester 57001 1394 Magneto Stator Coil Resistance Connections Tester Range Reading Tester Tester to x 100 Q BK W BK R 288 432 Q x lf there is more resistance than shown in the table or no hand tester reading infinity the stator has an open lead and must be replaced A much lower reading than this resistance means that the stator coil is shorted and must be replaced ELECTRICAL SYSTEM 14 11 Ignition System Troubleshooting Faulty ignition Malfunctioned engine Wiring and connect portion of the ignition No good system inspection gt Repair Good d i No good Spark plug inspection Replace No good Spark plug cap inspection Replace Good laniti il pri k volt ti No good Voltage is gnition coil primary peak voltage inspection less than the specified value Good No good Voltage is Voltage is specified none or almost none but faulty ignition Defective ignition coil Inspect 1 Adapter connection is incorrect or adapter is directive Inspection 1 Speed of cranking engine is slow Increase force of kicking engine Lower resistance in the t
7. 13 mm 0 3 0 5 in Clutch Friction Plate Thickness 2 8 2 9 mm 0 110 0 114 in Friction and Steel Plate Warp 0 15 mm 0 006 in or less Clutch Spring Free Length 35 0 mm 1 378 in Service Limit 2 7 mm 0 106 in 0 3 mm 0 012 in 34 0 mm 1 339 in Special Tools Outside Circlip Pliers 57001 144 Bearing Puller 57001 158 Clutch Holder 57001 1243 Flywheel Holder 57001 1313 Bearing Puller Adapter 57001 1526 Gear Holder 57001 1602 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 A WARNING The engine and exhaust system get extremely hot during normal operation and can cause serious burns Never touch the engine or exhaust pipe during clutch adjustment Clutch Cable Free Play Inspection e Slide the clutch lever dust cover A out of place e Check that the clutch cable upper end is fully seated in the adjuster B e Check that the clutch lever C has 8 13 mm 0 3 0 5 in of play D lf the free play is improper adjust the lever play Clutch Cable Free Play Adjustment e Slide the clutch lever dust cover out of place e Loosen the knurled locknut A e Turn the adjuster B so that the clutch lever will have 8 13 mm 0 3 0 5 in of play NOTE OBe sure that the outer cable end at the clutch lever is fully s
8. KXg85 Il Kawasaki KX100 Motorcycle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Fuel System Cooling System Engine Top End Engine Right Side Engine Removal Installation Engine Bottom End Transmission 7 Wheels Tires Final Drive Brakes Suspension Electrical System ech ech ech 01 gt sch O VO 0 O OT rbl NO Appendix KX85 KX85 I KX100 Kawasaki 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 amp 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
9. NAPE NAPF 3rd groove from the top 4th groove from the top 45 1 3 8 turns out 62 1 0 1 mm 0 04 0 04 in Service Limit Float height 19 1 mm 0 75 0 04 in een Air Cleaner Element Oil High quality foam air filter oil ES Reed Valve Reed Warp 0 2 mm 0 008 in Special Tools Fuel Level Gauge M18 x 1 0 57001 122 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 On the other hand if the throttle grip has no play the throttle will be hard to control and the idle speed will be erratic Check the throttle grip play periodically in accor dance with the Periodic Maintenance Chart and adjust the play if necessary The throttle cable routing is shown in Cable Wire and Hose Routing in the General Information chapter Free Play Inspection e Check the throttle grip free play B by lightly turning the throttle grip A back and forth lf the free play is improper adjust the throttle cable Throttle Grip Free Play Standard 2 3mm e Check that the throttle grip moves smoothly from full open to close and the throttle closes quickly and completely in all steering positions by the return spring If the throttle grip does not return properly check the throt tle cable routing grip free play and cable
10. e After the installation adjust each cable properly Cable Lubrication e Refer to the General Lubrication in the Appendix chapter Cable Inspection e Refer to the General Lubrication in the Appendix chapter 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 A dirty or damaged air cleaner can also alter the fuel to air ratio Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides If handlebar movement changes the idle speed the throt tle cable may be improperly adjusted or incorrectly routed or it may be damaged Be sure to correct any of these conditions before riding see Cable Wire and Hose Rout ing in the General Information chapter A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to be make sure to correct any of these conditions e Check the idle speed Adjust it as needed Idle Speed Adjustment e Start the engine and warm it up thoroughly e First turn in the air screw A until it seats lightly and back it out the specified
11. e Install the water hoses or breather hose being careful to follow the performed bends see Exploded View and Cable Wire and Hose Routing in the General Informa tion chapter Avoid sharp bending kinking flattening or twisting e Note the water hose clamp screw position and tighten the water hose clamps securely Torque Water Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in Ib 6D07000BS1 6D07001BS1 6D07060251 ENGINE TOP END 4 1 Engine Top End Table of Contents elole ere WN A ie o E OMe Sale cod dae eke oh daa dase ede Malar 4 2 el ET 4 3 A E EE 4 4 Compression Pressure Measurement AAA 4 4 AMO diana AET a naaa dia 4 4 Instala cine 4 5 Warpi Inspection POPE ARA O deg 4 5 Ill O 4 6 Cylinder Removal cesta lio dci clio idad clean 4 6 Cylinder Installation dede ANEN 4 6 O 4 7 PIStON Le EE ee EE 4 7 Cylinder Wear INSPCCHOM EE 4 8 Piston Diameter Measurement ooooccccccccncnonononeconcnonnnnnnnnnnnnnnnnnnnnnnnnnn nen nen rn nnnnnn nera nnnnenannaes 4 9 Piston Gylinder Clearance Inspection ies 4 9 Piston Ring Piston Ring Groove Inspection 4 10 Piston Ring End Gap Inspection EE 4 11 Piston Piston Pin and Connecting Rod Wear Inspection ooococonocccccncccccconananancnnnnnnnnnnos 4 11 Exhaust Valve RIP coins adas 4 13 Elle EE 4 13 Install vc Eeer 4 13 A RRA 4 15 Se lin A cv dari nities tates 4 15 Iert 4 15 Muffler Baffle Change 6 aia eege eege e deeg ee gees 4
12. or more e To determine which part is defective measure the arcing distance again with the spark plug cap removed from the ignition coil lead x lf the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug cap Measuring Coil Resistance If the arcing tester is not available the coil can be checked for a broken or badly shorted winding with an ohmmeter However an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage e Remove the ignition coil e Measure the primary winding resistance A OConnect the tester between the coil terminals OSet the tester to the x 1 Q range and read the tester e Measure the secondary winding resistance B OPull the spark plug cap off the lead e Connect an ohmmeter between the spark plug lead and the ground lead terminal e Set the meter to the x 1 kQ range and read the tester lf the meter does not read as specified replace the coil lf the meter reads as specified the ignition coil windings are probably good However if the ignition system still does not perform as it should after all other components have been checked test replace the coil with one known to be good Ignition Coil Winding Resistance Primary windings 0 36 0 48 Q x 1 Q Secondary windings 5 4 7 4 KQ x 1 KQ e Check the spark plug lead for visible dam
13. 1 0 N m 0 1 kgf m 9 in Ib on GC12008BSi C 6612060181 C 2 20 FUEL SYSTEM Fuel Hose Fuel Hoses and Connections Inspection OCheck 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 x Replace the fuel hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are tightened correctly e When installing route the hoses according to Cable Wire and Hose Routing section in the General Information chapter e When installing the fuel hoses avoid sharp bending kink ing flattening or twisting and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed Replace the hose if it has been sharply bent or kinked GSO5009BS1 COOLING SYSTEM 3 1 Cooling System Table of Contents See WEE 3 2 GOOIING SYSTEM EEN 3 3 o E A E A E A 3 4 Ree ET EE ER 3 5 Coolant Level Me en E 3 5 Coolant Deterioration INSPOCUON EEN 3 5 Coclant KT EE 3 6 RS OO IAAL NMG a EE 3 6 Cooling System Pressure Testing siii d 3 8 Cooling System Flushing EE 3 8 Water PUMP EE 3 9 Water Pump Cover Removal tcs EE 3 9 Water Pump Cover Installation ccoo des 3 9 Impeller e EE 3 9 Impeller Installation Zoe geed See Eege ee E
14. 6Kk040601S1 6K04010BS1 6K04060281 FINAL DRIVE 9 5 Drive Chain NOTE Oln wet and muddy conditions mud sticks to the chain and sprockets resulting in an overly tight chain and the chain may break e Check the rear brake see Brakes chapter A 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 Wheel Alignment Adjustment e Check that the notch A on the left chain adjuster B aligns with the same swingarm mark C as the right align ment indicator lf they are not adjust the chain slack and align the wheel alignment see Drive Chain Slack Adjustment NOTE OWheel alignment can also be checked using the straightedge or string method GKO40603S1 A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned Wear Inspection e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x lf there is any irregularity replace the drive chain Lubricate the drive chain if it appears dry see this chap ter A Bushing
15. 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 Wheels Inspection e Place a stand or the jack under the frame so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Spin the wheel lightly and check for roughness or binding If roughness or binding is found replace the hub bearings e Visually inspect the front and rear axles for damage lf the axle is damaged or bent replace it Spoke Inspection e Check that all the spokes are tightened evenly lf spoke tightness is uneven or loose tighten the spoke nipples to the specified torque evenly Torque Spoke Nipples 1 5 3 0 N m 0 15 0 31kgf m 13 27 in Ib e Check the rim runout see Rim Inspection A WARNING A missing spoke places an additional load on the other spokes which will eventually cause other spokes to break creating the potential for an accident resulting in serious injury or death Immediately replace any broken spoke s Rim Inspection e Remove the wheel and support it with the tire by the axle e Measure the rim runout axial A and radial B with a dial gauge x lf the rim runout exceeds the service limit check the hub bearings Replace them if they are damaged lf the problem is not due to the bearings correct the rim warp runout A certain amount of rim warp can be cor rected by recentering the rim Lo
16. Ignition so A att etien 14 13 Igntion Cal Instala EE 14 13 Ignition Coil MSPS CMON EE tea ca Sentheeet amas edcawieacen ateeasacceatnuh sarees nenene 14 13 Spark Plug Cleaning and INSPOCHON EE 14 15 Spark Plug Gap WS PSC WEE 14 15 CDI Unit INSPECTION EE 14 15 Engine Stop Button Electric Current Inspechon EE 14 16 14 2 ELECTRICAL SYSTEM Exploded View A e E ASS A GP02299BW4 C 0 JO Om P ob Engine Stop Button CDI unit Ignition Coil Spark Plug Magneto Stator Crankshaft Sensor Magneto Flywheel KX85 A1 A5 B1 B5 KX100 D1 D5 T1 9 8 N m 1 0 kgf m 87 in lb T2 T3 T4 T5 Apply silicone sealant Liquid Gasket 29 N m 3 0 kgf m 22 ft lb 26 N m 2 7 kgf m 20 ft lb 5 2 N m 0 53 kgf m 43 in lb 8 8 N m 0 90 kgf m 78 in lb TB1211 56019 120 ELECTRICAL SYSTEM 14 3 Wiring Diagram KX85 A1 A5 B1 B5 KX100 D1 D5 Engine Stop Button Ignition Coil Color Code Bk Black CDI Unit 6 Green o Orange R Rea W White Crankshaft Sensor KX85 A6F B6F KX100 D6F Magneto GP05081BW2 C Engine Stop Button Ignition Coil Color Code e Bk Black Magneto 6 Green o Orange R Rea CDI Unit 7 7 w white Crankshaft 4 Sensor GPO5082BW2 C 14 4 ELECTRICAL SYSTEM Specifications Item Magneto Flywheel Magne
17. maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts as to his ability to do the work all ad justments 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 thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation To get the longest life out of your motorcycle e Follow the Periodic Maintenance Chart in the Service Manual eBe alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki Motorcycles are introduced by the Service Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance 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
18. or hard increase the tire pressure to prevent damage or punctures through the tires will skid more easily 6y05060451 GJ05010381 WHEELS TIRES 8 11 Tires Inspection As the tire tread wears down the tire becomes more sus ceptible the puncture and failure e Remove any imbedded stones or other foreign particles from the tread e Visually inspect the tire for cracks and cuts replacing the tire in case of bad damage Swelling or high spots indi cate internal damage requiring tire replacement A WARNING Some replacement tires may adversely affect han dling and cause an accident resulting in serious in jury or death To ensure proper handling and sta bility use only the recommended standard tires for replacement inflated to the standard pressure NOTE OCheck and balance the wheel when a tire is replaced with a new one 8 12 WHEELS TIRES Hub Bearing Wheel Bearings Removal e Remove the following Wheel see Wheel Removal Oil Seals and Circlips e Use the bearing remover to remove the hub bearings A Special Tool Bearing Remover Shaft 69 57001 1265 B Bearing Remover Head 10 x 12 57001 1266 C Inside Circlip Pliers 57001 143 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 the disc does not touch the ground Installation e Before installing the wheel
19. the fork fully oil will be forced from between the tubes into the inner tube through the holes at the top of it This raised the oil level in the inner tube If the fork is extended to the full length of its normal travel the oil level will be raised about 30 mm 1 18 in e After purging the air from the assembly let it sit for about five minutes so that any suspended air bubbles can sur face lt Adjusting Oil Level gt e Check the oil level OWith the fork fully compressed put the oil level gauge A on the top of the tube B and inspect the distance from the top of the outer tube to the oil NOTE OThe gauge tube is graduated in 1 cm division OThe gauge body is graduated in 10 mL 0 134 US oz division excluding the gauge tube of about 5 mL 0 17 guoaosaisi c US oz capacity Oil Level fully compressed without spring Standard KX85A 100 2 mm 3 9 0 08 in KX85B KX100D 90 2 mm 3 5 0 08 in Adjustable Range KX85A 75 115 mm 3 0 4 5 in KX85B KX100D 75 115 mm 3 0 4 5 in If no oil pumped out there is insufficient oil in the fork tube Pour in enough oil then pump out the excess oil e Install the parts removal see Assembly 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
20. 1 75 57001 252 Bearing Driver 632 57001 382 ST5701438T Outside Circlip Pliers 57001 144 ST5701448ST Bearing Puller 57001 158 ST5701588T ST5703828T Piston Pin Puller Assembly 57001 910 ST5709108ST Rim Protector 57001 1063 ST571063ST 1 20 GENERAL INFORMATION Special Tools and Sealants Bead Breaker Assembly 57001 1072 T5710728T Head Pipe Outer Race Press Shaft 57001 1075 ST5710758T Steering Stem Bearing Driver Adapter 29 7 57001 1092 ST5710928T Crankcase Splitting Tool Assembly 57001 1098 ST571098ST Steering Stem Nut Wrench 57001 1100 ST5711008T Head Pipe Outer Race Driver 46 5 57001 1106 ST5711068T Head Pipe Outer Race Remover ID gt 37 mm 57001 1107 ST5711078T Bearing Driver Set 57001 1129 ST5711298T Compression Gauge Adapter M14 x 1 25 57001 1159 ST5711598T Crankshaft Jig 57001 1174 ST5711748T GENERAL INFORMATION 1 21 Special Tools and Sealants Fork Outer Tube Weight Fork Spring Holder 57001 1218 57001 1286 ES T5712188T ST15712868T Jack Fork Oil Level Gauge 57001 1238 57001 1290 T15712388T ST5712908T Clutch Holder Fork Piston Rod Puller M10
21. 15 4 2 ENGINE TOP END Exploded View GE02295BW4 C 1 KIPS Chamber Vent Tube KX85A6F B6F KX100D6F T1 3 9 N m 0 40 kgfm 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 R Replacement parts ENGINE TOP END 4 3 Specifications Item Standard Service Limit Cylinder Head Cylinder Compression Cylinder Head Warp Usable range 825 1 280 kPa 8 4 13 0 kgf cm 119 185 psi 0 03 mm 0 0012 in Cylinder Piston Cylinder Inside Diameter KX85A B KX100D Piston Diameter KX85A B KX100D Piston cylinder Clearance KX85A B KX100D Piston Ring groove Clearance Top KX85A B KX100D Second Piston Ring Groove Width Top KX85A B KX100D Second Piston Ring Thickness Top second Piston Ring End Gap Top Second 48 505 48 520 mm 1 9096 1 9102 in 52 505 52 520 mm 2 0671 2 0677 in 48 439 48 454 mm 1 9070 1 9076 in 48 444 48 459 mm 1 9072 1 9078 in KX85 A4 B4 52 435 52 450 mm 2 0644 2 0650 in 0 061 0 071 mm 0 0024 0 0028 in 0 056 0 066 mm 0 0022 0 0026 in KX85 A4 B4 0 065 0 075 mm 0 0026 0 0030 in 0 020 0 060 mm 0 0008 0 0024 in 0 040 0 080 mm 0 0016 0 0031 in 0 020 0 060 mm 0 0008 0 0024 in 1 01 1 03 mm 0 0398 0 0406 in
22. 17 2 17 2 17 2 18 2 18 2 18 2 19 2 19 2 19 2 19 2 20 2 20 2 2 FUEL SYSTEM Exploded View OA a Ki e e H GC02250BW4 C Y EN i AY Sy 1 Throttle Cable T1 1 0 N m 0 10 kgf m 9 in lb 2 Pilot Screw T2 8 8 Nm 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 Pilot Jet G Apply grease 6 Main Jet O Apply oil 7 Float Valve Exploded View FUEL SYSTEM 2 3 ch l OOONDOARWDND ch Fuel Tank Cap Gasket Fuel Filler Fuel Tank Fuel Tap Air Cleaner Housing Holder Air Filter Plate Air Cleaner Element Holder Air Cleaner Element Air Duct 6C02372BW4 C Fuel Tap KX85A6F B6F KX100D6F 0 8 N m 0 08 kgf m 7 in lb 8 8 N m 0 90 kgf m 78 in lb 3 0 N m 0 31 kgf m 27 in lb Apply engine oil Apply Grease Apply 2 stroke racing oil or high quality foam air filter oil Replacement Parts 2 4 FUEL SYSTEM Specifications Item Throttle grip free play and Cable Carburetor Make type Main Jet KX85A B KX100D Main air jet Throttle Valve Cutaway Jet Needle KX85A B KX100D Jet Needle Clip Position KX85A B KX100D Pilot Jet Slow jet Air Screw Starter Jet Service Fuel Level below the float bowl mating surface Standard 2 3 mm 0 08 0 12 in KEIHIN PWK28 140 138 60 3 5
23. B using the piston to locate the ring squarely in place e Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap between the ends of the ring with a thick ness gauge C If the gap is wider than the service limit the ring is over worn and must be replaced 6E060106S1 Piston Ring End Gap Top and Second Standard 0 30 0 50 mm 0 0118 0 0197 in Service Limit 0 80 mm 0 0315 in Piston Piston Pin and Connecting Rod Wear lf the ring shows weakness or deformation replace the ring Also if the pin hole groove shows excessive wear replace the piston e Measure the diameter of the piston pin D with a microm eter lf the piston pin diameter is less than the service limit at any point replace the piston pin e Using a cylinder gauge measure the diameter of both piston pin holes B in the piston and the inside diameter of the connecting rod small end x lf either piston pin hole diameter exceeds the service limit replace the piston lf the inside diameter of the connecting rod small end ex ceeds the service limit replace the crankshaft assembly e Check the needle bearing C OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring in spect the bearing for abrasion color change other dam age Inspection e Visually inspect the snap ring A still fitted in place 6E060604S
24. B 7 5 mm 0 30 in 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 e 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 e Recheck the runout with a dial gauge repeating the process until the runout falls within the service limit SE OVertical misalignment is corrected either by driving a wedge in between the flywheels or by squeezing the flywheel rims in a vise depending on the nature of the misalignment In cases of both horizontal and vertical misalignment correct the horizontal misalignment first x If flywheel misalignment cannot be corrected by the above i method replace the crankpin or the crankshaft itself Eee ie ES Don t hammer the flywheel at point A 6105008BS2 C ENGINE BOTTOM END TRANSMISSION 7 13 Transmission Transmission Shaft Removal e Split the crankcase see Crankcase Splitting e Pull off the shift rods A and disengage the shift fork guide pins from the shift drum grooves e Remove the shift drum B e Remove the shift forks C from the transmission gears e Take out the drive shaft D and output shaft E together with their gears meshed Tr
25. Body Lower End A 31 35 mm 1 22 1 38 in B Gas Reservoir C Oil Capacity 161 mL 5 44 US oz e Insert the piston end A of the push rod assembly into the rear shock body slowly Do not insert the seal assembly B yet Pump the push rod until all the air is forced out of the rear shock body C e Push the seal assembly into the rear shock body until it just clears the circlip groove e Check the circlip If it is deformed or damaged replace it with a new one e Fit the circlip A into the groove in the rear shock body B NOTICE If the circlip is not a certain fit in the groove in the rear shock body the push rod assembly may come out of the shock absorber when injecting the nitro gen gas or riding the motorcycle e Pull up the push rod assembly C against the circlip A e Force the stop D into the rear shock body by lightly tap ping around the edge of the stop with a mallet e Hold the lower end of the push rod assembly with a vise e Pump the rear shock up and down several times and then leave it in the fully extend position for about three minutes e Remove the air bleeder bolt E from the upper part of the rear shock body 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 ai
26. Connecting rod big end seizure Transmission gear or bearing seizure Kick shaft return spring broken Kick ratchet gear not engaging No fuel flow No fuel in tank Fuel tap turned off Tank cap air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level too high Float valve worn or stuck open Starting technique faulty when flooded kick with the throttle fully open to allow more air to reach the en gine No spark spark weak Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trou ble Spark plug cap not in good contact Spark plug incorrect C D I Unit trouble Ignition coil trouble Ignition coil resistor open Flywheel magneto damaged Wiring shorted or open Fuel air mixture incorrect Idle adjusting screw maladjusted Slow jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter jet clogged Compression Low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring land clearance excessive Cylinder head gasket damaged Cylinder head warped Cylinder base gasket damaged Read valve damaged Cylinder nut loose Poor Running at Low Speed Spark weak Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect C D I Unit trouble Crankshaft s
27. Cover Shift Pedal Clutch see Clutch Removal e Pull out the shift shaft with the shift mechanism arm and arm spring e Remove the gear set lever spring A e Remove the bolt and take off the gear set lever B Installation e Before installing the shift shaft apply high temperature grease to the oil seal lips e Install the following Clutch see Clutch Installation Brake Pedal see Brakes chapter e Torque Torque Gear Set Lever Mounting Bolts 9 8 N m 1 0 kgf m 87 in Ib Inspection e Check the shift shaft A for bending or damage to the splines lf the shaft is bent straighten or replace it If the splines are damaged replace the external shift mechanism e Check the return spring B and arm spring C for cracks or distortion x lf the springs are damaged in any way replace them e Check the shift mechanism arm D for distortion lf the shift mechanism arm is damaged in any way re place the shift mechanism e Check that the return spring pin is not loose xf it is loose unscrew it apply a non permanent locking agent to the threads and tighten it to the specified torque Torque Shift Shaft Return Spring Pin 22 N m 2 2 kgf m 16 ft lb e Check the gear set lever and the spring for cracks or distortion x If the lever or spring is damaged in any way replace them GRO70601S1 ENGINE RIGHT SIDE 5 19 Kickstarter Removal e Remove the following parts Right Engine Co
28. EE 6 3 Installation td sa 6 4 6 2 ENGINE REMOVAL INSTALLATION Exploded View GHO20604W3 C T1 29 N m 3 0 kgf m 22 ft lb T2 69 N m 7 0 kgf m 51 ft lb ENGINE REMOVAL INSTALLATION 6 3 Engine Removal Installation Removal e The following parts may be removed with the engine in the frame Clutch see Engine Right Side chapter Flywheel Magneto see Electrical System chapter e Remove the following Engine Oil drain see Engine Bottom End Transmission chapter Coolant drain see Cooling System chapter Seat see Frame chapter Fuel Tank see Fuel System chapter Radiators see Cooling System chapter Muffler see Engine Top End chapter Carburetor see Fuel System chapter Clutch Cable Lower End see Engine Right Side Drive Chain see Final Drive chapter Shift Pedal Kick Pedal Rear Brake Reservoir Spark Plug Cap e Disconnect the magneto leads connector A engine stop button lead and ignition coil lead connectors or plugs and remove the ground lead terminal bolt e Place a jack under the frame to lift the rear wheel off the ground see Wheels Tires chapter Special Tools Jack 57001 1238 e Squeeze the brake lever slowly and hold it with a band A WARNING Motorcycle may fall over unexpectedly resulting in an accident or injury Be sure to hold the front brake when removing the engine e Remove the engine mounting bolts B and bracket bolts A A WARNING Since the
29. Fuel Level Inspection If the fuel level is incorrect inspect the rest of the carbu retor before correcting it e Pull the carburetor cable to check that the throttle valve moves smoothly and returns by spring pressure If the throttle valve does not move smoothly replace the carburetor body so that it returns by spring force 2 14 FUEL SYSTEM Carburetor e Clean the carburetor see cleaning e Check the plastic tip A of the float valve needle B It should be smooth without any grooves scratches or tears lf the plastic tip is damaged C replace the needle e Push the rod D in the valve then release E it If the rod does not spring out replace the valve e Check the jet needle and needle jet for damage The damaged jet needle should be replaced If the needle jet is damaged replace the carburetor body e Check the starter jet in the float bowl for damage If the starter jet is damaged replace the float bowl 6006014351 C FUEL SYSTEM 2 15 Air Cleaner Air Cleaner Element Removal e Remove the side cover e Remove the wing bolt A and pull out the element B Air Cleaner Element Installation e Coat the lip of the element A with a thick layer of all purpose grease B to assure a complete seal Also coat the air cleaner housing where the lip of the element fits 6C070601S1 e Align the element tab A with the projection B on the air cleaner
30. 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 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 Items KX85 A1 A5 A6F AAF KX85 B1 B5 B6F BAF Dimensions Overall Length 1 820 mm 71 7 in 1 910 mm 75 2 in Overall Width 735 mm 28 9 in Overall Height 1 055 mm 41 5 in 1 105 mm 43 5 in Wheelbase 1 255 mm 49 4 in 1 290 mm 50 8 in Road Clearance 340 mm 13 4 in 380 mm 15 0 in Seat Height 840 mm 33 1 in 870 mm 34 3 in Dry Weight KX85 A1 ASF 65 kg 143 lb pee S ee Curb Weight KX85A9F 69 kg 152 Ib KX85B9F 71 kg 157 Ib Front 34 kg 75 lb 35 kg 77 Ib Rear 35 kg 77 lb 36 kg 79 Ib Fuel Tank Capacity 5 5 L 5 8 US qt Engine Type 2 stroke single cylinder piston reed valve Liquid cooled 48 5 x 45 8 mm 1 91 x 1 80 in 84 cm 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 m
31. To avoid injury do not point the reservoir valve toward your face or body when releasing nitrogen gas pressure since an oil mist is often released with the nitrogen Always re lease nitrogen gas pressure before disassembling the rear shock absorber to prevent explosive sepa ration of parts Never incinerate a shock absorber 6M050624S1 6M050622S1 11 22 SUSPENSION Swingarm Removal e Squeeze the brake lever slowly and hold it with a band e 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 e Pull out the swingarm pivot shaft and remove the swingarm C Installation e Installation is the reverse of removal Note the following e Apply plenty of molybdenum disulfide grease to the inside of the needle bearings and sleeves e Torque Torque Swingarm Pivot Shaft Nuts 69 N m 7 0 kgf m 51 ft Ib Tie Rod Nuts 59 N m 6 0 kgf m 44 ft lb e Install the caliper holder A on the swingarm stop B e Install the following Rear Wheel see Wheels Tires chapter Drive Chain see Final Drive chapter e Check the brake after installation A 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 resultin
32. 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 informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the ignition coil section Whenever you see symbols heed their in structions Always follow safe operating and maintenance practices 44 DANGER DANGER indicates a hazardous situa tion which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situa tion which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a hazardous situa tion which if not avoided could result in minor or moderate injury 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 OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural st
33. and Cable ccceeeeceeeeeeeeee Free Play Inspection eeeeee Free Play Adustment AAA Installation Notes Cable Lubrication sus csssnataeediatsdcnceks Cable Inspection AA Eer ege dada Idle Speed Inspection Idle Speed Adlustment Main Jet Replacement Notes Service Fuel Level Inspection Service Fuel Level Adjustment Fuel System Cleam REMOVALS iaa da Installation enneren eneee Disasseribll acia A le sate ee E Cleaning EE ef ee Maid Ari aaa dica Air Cleaner Element Removal Air Cleaner Element Installation Air Cleaner Element Cleaning and Inspection ooccocinncccccnnnnccccccnonancncnnnancnnnnnnnc cnn nannncncncnns Air Cleaner Housing Removal Air Cleaner Housing Installation Air Cleaner Housing Assembly Fuel Tankian di Fuel Tank Removal seeen Fuel Tank Installation ooooooninnnnnnnnnnn Fuel Tap Hemoval Fuel Tap Installation ooooooncnnnnnnnnn Fuel Tap Inspection Fuel Tank Cap Inspection ee Fuel Tank and Tap Cleaning sessseeeenn Reed Valve cents A EE Installation Note n pl sei F el ele A ieee Fuel Hoses and Connections Inspection 2 2 2 4 2 5 2 5 2 5 2 6 2 6 2 6 2 7 2 7 2 7 2 7 2 8 2 9 2 9 2 10 2 11 2 12 2 12 2 13 2 13 2 15 2 15 2 15 2 15 2 16 2 16 2 16 2 17 2 17 2
34. dust is allowed to pass through into the carburetor the throttle may become stuck possibly causing accident Replace the air cleaner element according to the maintenance chart If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur FUEL SYSTEM 2 11 Carburetor Installation e Being careful not to bend or otherwise damage the jet needle B insert the throttle valve assembly A into the carburetor body OCheck to see that the throttle valve goes all the way down into the carburetor body and slides smoothly e Fit the ridge A into the notch B on the carburetor holder e Tighten the clamps A securely Torque Carburetor Clamp Screws 1 5 N m 0 15 kgf m 13 in Ib e Route the air vent and overflow hose through the clamp on the crankcase see Cable Wire and Hose Routing Section in the Appendix chapter Always keep the hoses free of obstruction and make sure they do not get pinched by the chain or shock absorber e Turn the fuel tap to the ON position and check for fuel leakage from the carburetor A WARNING Fuel spilled from the carburetor is hazardous OAgjust the following items if necessary Throttle Cable see Throttle Grip Free Play Adjustment Idle Speed see Idle Speed Adjustment 2 12 FUEL SYSTEM Carburetor Disassembly A WARNING Gasoline is extremely flammable and can be ex plosive under certai
35. e Install the front master cylinder see Front Master Cylinder Installation in the Brakes chapter Clutch Lever Installation e Install the clutch lever so that the mating surface A of the clutch lever clamp is aligned with the punch mark B Torque Clutch Lever Clamp Bolts 8 8 N m 0 90 kgf m 78 in Ib 6N06012BS1 GFO4015BS1 STEERING 12 5 Steering Adjustment e Check the steering OLift the front wheel off the ground using a stand and the jack Special Tool Jack 57001 1238 OWith 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 x If the wheel binds or catches before the stop the steering is too tight OFeel for steering looseness by pushing and pulling the legs If you feel looseness the steering is too loose NOTE OThe cables hose and wiring will have some effect on the motion of the fork which must be taken into account Be sure the wire hose and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid Adjust the steering if necessary e Remove the following parts Number Plate Stem Head Nut A loosen Fork Lower Clamp Bolts both sides loosen e Move back the fuel tank with the hose installed see Fuel System chapter e Adjust the steering with the
36. holder special tool e Raise the outer tube and screw the top plug into it e Install the front fork see Front Fork Installation e Tighten the top plug to the specified torque Torque Front Fork Top Plugs 27 N m 2 8 kgf m 20 ft Ib Spring Tension e Since a fork spring A becomes shorter as it weakens check its free length B to determine it condition lf the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability Main Spring Length Standard 430 mm 16 9 in Service Limit 422 mm 16 6 in GM040619S1 GM040620S1 6M040413S1 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 e To adjust the compression damping force turn the upper damping adjuster A to the desired position aligning the punch mark B OThe standard setting is number 2 position x lf the damping feels too soft or too stiff adjust it Compression Damping Adjustment Position 1 2 3 4 Damping Force Minimum lt Maxi
37. inside of new needle bearings and sleeves e Be sure to install the needle bearings so that the manu facturer s marks are faced out OPosition the bearings as shown in the Exploded View us ing a suitable bearing driver in the bearing driver set Special Tool Bearing Driver Set 57001 1129 Uni Trak Link Pivot Inspection e Check the pivot of the swingarm and uni trak link tie rod and rocker arm for wear periodically or whenever exces sive play is suspected see Swingarm Pivot Inspection e A small amount of play on the pivot is normal and no cor rective action is needed However if excessive play is felt check the swingarm and uni trak link bearings for wear and replace them if necessary see Rocker Arm Tie Rod Bearing Inspection Rocker Arm Tie Rod Bearing Inspection e The rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing installed for abrasion color change or other damage If there is any doubt as to the condition of any of the nee dle bearings replace all the sleeves and needle bearings as a Set Rocker Arm Tie Rod Sleeve Inspection lf there is visible damage replace the sleeves and all the needle bearings as a set 6M070601S1i STEERING 12 1 Steering Table of Contents Exploded VIEW dese g eegente eege Eege deg 12 2 Ee 12 3 Sui NEE 12 4 Instala oi iio EE 12 4 Cliteh Lever instala o
38. leakage A WARNING After servicing it takes several applications of the brake lever or 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 lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc 6L060601Si 10 12 BRAKES Brake Pads Brake Pad Wear Inspection e Check the lining thickness A of the pads in each caliper x 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 Service Limit 1 mm 0 04 in A BRAKES 10 13 Master Cylinder Front Master Cylinder Removal e Drain the front brake fluid see Brake Fluid Change e Remove the following Brake Hose Banjo Bolt A Master Cylinder Clamp Bolts e Remove the front master cylinder B Front Master Cylinder Installation e Position the master cylinder so that the vertical parting line A of the master cylinder clamps align with the punch mark B on the handlebar e The master cylinder clamp must be installed with the ar row mark A upward e Tighten the upper clamp bolt B first and then the lower clamp bolt C to the specified torque There will be a gap at the lower part of the
39. level in front reservoir is lower than the lower level line fill the reservoir to the upper level line Inside the front reservoir is stepped end showing the upper level line D OThe rear reservoir C must be kept more than half full with brake fluid If the amount of brake fluid is insufficient add brake fluid Brake Fluid Change In accordance with the Periodic Maintenance Chart change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water Furthermore the brake fluid should be changed to bleed the air quickly and completely whenever the brake line parts are removed A WARNING Mixing brands and types of brake fluid can reduce the brake system s effectiveness and cause an ac cident resulting in injury or death Do not mix two brands of brake fluid Change the brake fluid in the brake line completely if the brake fluid must be re filled but the type and brand of the brake fluid that is already in the reservoir are unidentified Recommended Disc Brake Fluid Type DOT 4 NOTE OThe procedure to change the front brake fluid is as fol lows Changing the rear brake fluid is the same as for the front brake GLO90607S1 BRAKES 10 19 Brake Fluid e Level the brake fluid reservoir e Remove the reservoir cap and the rubber cap B on the bleed valve A e Attach a clear plastic hose C to the bleed valve on the caliper and run t
40. lightly polish the piston with fine emery cloth e Clean carbon and dirt out of the piston ring groove using a suitable tool NOTICE Carbon particles can be very abrasive to piston ring Don t allow such particles to fall onto the cylinder walls e The top A and second B rings are identical in KX100 model But they are different in KX85 model OThe mark on the ring are as follows KX85A B Top 1N Second 2N KX100D Top and Second N e First fit one end of the piston ring against the pin in the ring groove spread the ring opening with the other hand and then slip the ring into the groove Olnstall each ring so that the marked C side faces upward 6E060601S1i 6E1606068S1 o 6E06060381 o 4 8 ENGINE TOP END Cylinder Olnstall the ring so that the pin A in the piston ring groove is between the ends of the piston ring e Apply 2 stroke engine oil to the connecting rod needle bearing and the piston pin e Install the piston so that the IN marked on the piston side wall comes to the back side of the engine e When installing a piston pin snap ring compress it only enough to install it and no more Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Fit anew piston pin snap ring A into the side of the piston so that the ring opening B does not coincide with the notch C in the edge of the pis
41. 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 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 dam ages 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 c
42. number of turns Air Screw turns out Standard 1 3 8 e Turn the idle adjusting screw B to obtain desired idle speed If no idle is preferred turn out the screw until the engine stops e Open and close the throttle a few times to make sure that the idle speed is as desired Readjust if necessary Main Jet Replacement Notes A 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 this includes any appliance with a pilot light Make sure the engine is cold before working Wipe any fuel off the engine before starting it 2 8 FUEL SYSTEM Carburetor e Turn the fuel tap to the OFF position e Remove the fuel tank e Place a suitable container beneath the carburetor drain plug e Remove the carburetor see Carburetor Removal e Remove the drain plug to drain the carburetor e Replace the main jet A with the desired one e Tighten the drain plug securely e Install the carburetor see Carburetor Installation Service Fuel Level Inspection A 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 this includes any appliance with a pilot light e Turn the fuel tap to the OFF posi
43. or 4 9 or 43 in lb Handlebar Holder Bolts 25 18 S Front Master Cylinder Clamp Bolt 8 8 78 in lb Clutch Lever Clamp Bolts 8 8 78 in lb Frame Rear Frame Pipe Bolts 34 25 Rear Fender Flap Bolts 5 9 52 mb Electrical System Spark Plug 26 20 Magneto Cover Bolts 9 8 87 in lb Flywheel Nut 29 22 Stator Mounting Screws 5 2 43 in lb Ignition Coil Mounting Bolts 8 8 78 in lb CDI Unit Mounting Bolts 8 8 78 in lb 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 Basic Torque for General Fasteners Threads dia Torque mm N m kgf m ft lb 5 3 4 4 9 0 35 0 50 30 43 in lb 6 5 9 7 8 0 60 0 80 52 69 in lb 8 14 19 1 4 1 9 10 0 13 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 33 165 240 Special Tools and Sealants GENERAL INFORMATION 1 19 Fuel Level Gauge M18 x 1 0 57001 122 SS 8757012297 Bearing Puller Adapter 57001 136 ST5701368T Inside Circlip Pliers 57001 143 Compression Gauge 20 kgf cm 57001 221 T5702218T Flywheel Puller M12 x
44. or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually dete riorate the rubber used in the disc brake When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE 10 6 BRAKES Brake Lever and Pedal Brake Lever Play Adjustment e Adjust the front brake lever A to suit you e Loosen the adjuster locknut C and turn the adjuster D to either side e After adjustment tighten the locknut to the specified torque Torque Brake Lever Adjuster Locknut 4 9 N m 0 50 kgf m 43 in Ib A WARNING An improperly adjusted brake could drag and cause the brake to overheat damaging the brake assem bly and possbily locking the rear wheel resulting in loss of control Always maintain the proper brake adjustment Pedal Position Adjustment The brake pedal position and pedal play should not be adjusted There is no
45. pedal position adjustment device as such The only adjustment is master cylinder push rod length NOTE OUsually it is not necessary to adjust the push rod length but always adjust it when the rear master cylinder A is disassembled OWhen the brake pedal is in its rest position measure the length B indicated in the figure B 57 5 mm 2 26 in C Push Rod Locknut If the length is not within the specified length adjust the clevis A as follows OLoosen the push rod locknut B OPull out the cotter pin C and the joint pin D OTurn the clevis to obtain the specified length OTighten the locknut Torque Rear Master Cylinder Push Rod Locknut 18 N m 1 8 kgf m 13 ft lb Olnstall the joint pin and new cotter pin NOTE Olf the pedal position is incorrect after adjusting the mas ter cylinder push rod the brake pedal may be deformed or incorrectly installed 6L040601S1 6L04002BS1 6L04060281 BRAKES 10 7 Brake Lever and Pedal Pedal Removal e Remove the following Brake Pedal Return Spring A Cotter Pin Joint Pin B e Remove the brake pedal bolt C and remove the brake pedal D GLO40603S1 Pedal Installation Notes e Grease the brake pedal hole e Check the pedal O ring for signs of damage If necessary replace them with new ones e Install the brake pedal to the frame and tighten the brake pedal bolt with the specified tor
46. plate and install the element Air Cleaner Element Cleaning and Inspection NOTE Oln dusty areas the element should be cleaned more frequently than recommended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately Olf there is a break in the element material or any other damage to the element replace the element with a new one A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the element in a well ventilated area and take care that there is no spark or flame any where near the working areas Do not use gasoline or low flash point solvents to clean the element 2 16 FUEL SYSTEM Air Cleaner e Remove the air cleaner element and separate the ele ment A from the frame B GC07060281 e Clean the element in a bath of a high flash point solvent and squeeze the element dry e Check all the parts of the element for visible damage lf any part of the element is damaged replace it e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess then wrap it in a clean rag and squeeze it as dry as possible Be careful not to tear the sponge filter e Assemble the element Air Cleaner Housing Removal e Remove Seat Side Cover Air Cleaner Duct Clamp loosen Rear Frame Pipe A Air Cleaner Housing Bolts B e Remove the air cleaner housi
47. play excessive Clutch plate warped or too rough Clutch spring tension uneven Transmission oil deteriorated Transmission viscosity too high Transmission oil level too high Clutch housing frozen on drive shaft Clutch release mechanism trouble Friction plates installed incorrectly Gear Shifting Faulty Doesn t into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear set lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift drum broken Jumps out of gear Shift fork worn Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear set lever spring weak or broken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear set lever spring weak or broken Shift mechanism arm spring broken Abnormal Engine Noise Knocking Ignition timing maladjusted C D I Unit trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure or damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con n
48. pre viously 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 Lead cross section Color Indicated on the Lead Color Indicated on the Wiring Diagram Red Lead Strands Yellow Red Y Rass Yellow Red 6B02069Bw1 C 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 Warp Bent Dent Scratch Wear Color change Deterioration Seizure 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 dete riorated performance replace the damaged parts GENERAL
49. rear wheel The difference between the highest and lowest dial gauge readings is the amount of runout warp lf the runout exceeds the service limit replace the rear sprocket Rear Sprocket Warp Standard TIR 0 4 mm 0 016 in or less Service Limit TIR 0 5 mm 0 020 in GKO5011181 BRAKES 10 1 Brakes Table of Contents Exploded MW dit 10 2 A seco tus Ea eaa A ae Eaa te ae Coane ORES 10 4 Disc Brake Information EE 10 5 B ake ever BS EE 10 6 Brake Lever Play AdjustMent oo o ccccccnnnnnnnccccccccconnnnnnnncnnonnnnnnnnnnnnnnrennnn nn nnnnnnn rn ran nnnennnnaes 10 6 Pedal Position AQUSIM EN iriri a 10 6 Redal FA GImiOval lacra dio rice Sa caes 10 7 P dal Installation Notes ci as 10 7 A eebe eege eege eat cree 10 8 Callper Rem ee Ee 10 8 Caliper Installation aii 10 8 Caliper DisassomblyY cuisine 10 8 E le Ale a coles dano 10 9 Fluid Seal Damage Inspection cirios dias 10 9 Dust Seal and Cover Damage Inspechon occ nnnnnnncnnnnnnnccns 10 9 Piston Cylinder Damage INSpection ccoo dai dado ca 10 9 Caliper Holder Shaft Wear Inspeccion as ii 10 10 A O 10 11 FRG OVA o EE EEEO ENEE EE sven A E TOE use 10 11 Installation et 10 11 Brake Pad Wear Inspector d e ege 10 12 Master ee EE 10 13 Front Master Cylinder Removal cs ociosa EE 10 13 Front Master Cylinder Installation omar litera 10 13 Rear Master Cylinder Removal vce occiso dees 10 13 Rear Master Cylinder Installation Notes AAA 10 13 Ins
50. smaller the front end becomes lighter due to change in weight bias Also it tends to understeer the results are opposite e Be sure the front tire doesn t rub the fender when the fork tubes are compressed fully Make the adjustment by 5 mm increments Fork Tube Height A KX85A 20 mm 0 79 in KX85B KX100D 0 mm 0 in NOTICE Both fork tube heights should be adjusted evenly Fork Oil Change each fork leg e Remove the front fork see Front Fork Removal e Remove the following see Fork Oil Level Adjustment Top Plug Spring Seat Main Spring A WARNING The top plugs are under extreme spring pressure and may eject with great force during service Use care when removing the top plugs Wear eye and face protection e Turn the front fork leg upside down and pour the oil into a container Pump the fork to drain the old oil completely e Pour in the type and amount of fork oil specified Recommended Fork Oil KHL15 10 KAYABA 01 or equivalent Fork Oil Capacity completely dry KX85A 315 4 mL 10 7 0 14 US oz KX85B KX100D 321 4 mL 10 9 10 14 US oz e Check the oil level SUSPENSION 11 9 Front Fork OWith 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 lf the oil is above or below the specified level remove or add oil and recheck the oil level e In
51. 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 see Removal e Insert the valve stem into the rim and screw the nut on loosely e Fit the rim protectors and use tire irons to install the tire bead NOTE OTo prevent rim damage be sure to place the rim protec tors at any place the tire irons are applied e Pry one side of the tire back onto the rim Fit the bead protector into the tire rear tire e Pry the other side of the tire onto the rim starting at the side opposite the valve OTake care not to insert the tire irons so deeply that the tube is damaged e Install the other side of the tire bead onto the rim in the same manner e Check that the tube is not pinched between the tire and rim e Tighten the bead protector nut rear wheel and valve stem nut and put on the valve cap e Check and adjust the air pressure after installing Air Pressure Inspection Adjustment e Using tire air pressure gauge A measure the tire pres sure when the tires are cold Adjust the tire air pressure to suit track conditions and rider preference but do not stray too far from the recom mended pressure Track Condition Tire Pressure OWhen the track is wet muddy 80 kPa 0 8 kgf cm 11 psi sandy or slippery reduce the tire pressure to increase the tire tread surface on the ground OWhen the track is pebbly 98 kPa 1 0 kgf cm 14 psi
52. stem nut wrench C Special Tool Steering Stem Nut Wrench 57001 1100 x lf the steering is too tight loosen the stem nut B a fraction of turn If the steering is too loose tighten the stem nut a fraction of turn NOTE OTurn the nut 1 8 turn at a time maximum e Tighten the following bolts and nut to the specified torque Torque Front Fork Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib Steering Stem Head Nut 64 N m 6 5 kgf m 47 ft Ib NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Check the steering again If the steering is still too tight or too loose repeat the ad justment e Install the parts removed GNO40601S1 12 6 STEERING Steering Stem Removal e 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 e 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 Special Tool Steering Stem Nut Wrench 57001 1100 Installation e Install the upper steering stem bearing see Steering Stem Bearing Installation e Grease the steering stem bearing see Steering Stem Bearing Lubrication e Install Stem Head Handlebar see Handlebar Installation Front Fork Legs see Suspension chapter Front Fender Steering Stem Head Nut e Route the cables wire and h
53. to a minimum Brake fluid quickly ruins painted or plated surfaces any spilled fluid should be completely washed away immediately e There is a flat washer on each side of the brake hose fitting Replace them with new ones when installing e When installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses according to the Cable Wire and Hose Routing section in the General Information chapter e Tighten the banjo bolts at the hose fittings to the specified torque Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Bleed the brake line after installing the brake hose see Bleeding the Brake Line Inspection e The high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace it if any cracks B or bulges C are noticed 6Lig0101si SUSPENSION 11 1 Suspension Table of Contents Exploded View cccseeeessenceees 11 2 Disassembhy teens 11 19 ELE 11 4 ASSOMDIY EE 11 20 Front POV K aiii io 11 5 Spring Tension cccocnccccccnnnccccccnnnnss 11 21 Air Pressure Adjustment Gell sne as 11 21 Compression Damping SUM a 11 22 Adjustment cuicos 11 5 Removal siones 11 22 Fork Oil Level Adjustment each Installation ira ea 11 22 ele EE 11 5 Swingarm Bearing Removal 11 22 Fork Clamp Position Adjus
54. 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 2000 Kawasaki Heavy Industries Ltd 10th Edition 1 Apr 8 2009 K LIST OF ABBREVIATIONS A ampere s lo pound s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celsius r revolution DC direct current rom revolution s perminute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s Q ohm s L liter s Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out
55. 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 lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc Caliper Disassembly e Remove the caliper see Caliper Removal e Remove the pads and spring see Pad Removal e Pull off the dust seal lip from the caliper body Front Caliper e Remove the caliper holder shaft rubber boot and dust cover e Using compressed air remove the piston OCover the caliper opening with a clean heavy cloth A ORemove the piston by lightly applying compressed air B to the hose joint opening AAA GLO506058S1 GLO506068S1 BRAKES 10 9 Calipers A WARNING The piston in the brake caliper can crush hands and fingers Never place your hand or fingers in front of the piston e Remove the dust seal and fluid seal e Remove the bleed valve and rubber cap Assembly Notes e Tighten the bleed valve to the specified torque Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e lt is recommended that the fluid seal B which is re moved be replaced with a new one e Replace the dust seals A if they are damaged e Apply brake fluid to the cylinders pistons and fluid seals piston seals and push the pistons C into the cylinders by hand Take care that neither the cylind
56. 0 03381 oz US cmHg x 1 333 kPa mL x 0 02816 oz imp mL x 0 06102 cu in Units of Speed km h x 0 6214 mph Units of Force N x 0 1020 kg N x 0 2248 lb Units of Power kg x 9 807 N kW x 1 360 PS kg x 2 205 Ib kw x 1 341 HP PS x 0 7355 kW PS x 0 9863 HP Units of Temperature F 3 40 20 0 20 40 104 5 F 40 40 C 176 212 248 284 80 100 120 140 160 180 200 220 240 260 280 300 F 320 40 20 eG 26 7 40 48 9 80 100 120 71 1 93 3 116 440 160 C MODEL APPLICATION Year Model Beginning Frame No Year Model Beginning Frame No JKBKXFACO1A000001 or JKBKXFACOI6A031001 or 2001 KX85 AT JKBKX085AAA000001 2006 KX85A6F JKBKX085AAA031001 JKVKXFBCO1A000001 or JKBKXFBCO6A015001 or 2001 KX85 B1 JKBKX085BBA000001 2006 KX85B6F JKBKX085BBA015001 JKAKXTDCO1A000001 or 2006 KX100D6F JKAKXTDCO6A018001 2001 KX100 D1 JKAKX100DDA000001 See Kxgsa7e YKBKXFACO7A036001 or JKBKXFACO2A007001 or JKBKX085AAA036001 2002 KX85 A2 JKBKX085AAA007001 2007 kxese7e YKBKXFBCO7A018001 or Sos uns pa YXBKXFBCO2A003001 or JKBKX085BBA018001 JKBKX085BB 1003001 2007 KX100D7F JKAKXTDCO7A021001 JKAKXTDCO2A004001 or JKBKXFACO8A040001 or 2002 KX100 D2 JKAKX100DDA004001 KX85A8F KBKXO8EAAA040001 JKBKXFACO3A015001 or JKBKXFBCO8A02001 or 2003 KX85 A3 JKBKX085AAA015001 KX85B8F KBKXO85BBA020001 2003 KX
57. 00 D3 The advancer assembly of the KX85 A3 B3 and KX100 D3 can be disassembled e Hold the bearing puller A in a vise and set the advancer assembly B with the gear upward on the bearing puller e Screw the rod C in and pull out the gear on the shaft Do not drop the assembly parts on the floor Special Tools Bearing Puller 57001 158 Bearing Puller Adaper 57001 1526 D 5 12 ENGINE RIGHT SIDE Right Engine Cover The advancer assembly consists of the following parts A Gear B Spring C Collar D Circlip E Ball bearing F Collar G Holder H Shaft I Ball J Guide e Check the advancer assembly parts for damage x Any damaged parts should be replaced with new ones e When assembling apply molybdenum disulfide grease between the shaft and inside outside diameter parts of the holder ball bearing and collars Advancer Assembly KX85 A3 B3 KX100 D3 e Press the gear A on the shaft so that the gear contacts the step on the shaft e Install the parts in due order and press fit the guide to set the distance C of 44 65 44 75 mm 1 7579 1 7618 in Right Engine Cover Assembly e Fit the advancer A to the lever shaft B as shown e Apply grease to the oil seal lips before inserting the lever shaft e Align A the mark B on the lever shaft with the mark C on the right engine cover and insert the shaft into the cover e Tighten Torque Lever Shaft Retaining Bolt D 5
58. 001 1238 e Hang the caliper with a brake hose on the swingarm e Pull out the axle e Move the rear wheel forward a little and free the drive chain from the rear sprocket e Move the rear wheel back to remove it 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 the disc does not touch the ground Olnsert a wood wedge between the brake pads This pre vents them from being moved out of their proper position should the brake pedal be squeezed accidentally Rear Wheel Installation e Installation is the reverse of removal Note the following e Grease the following Grease Seals Inner Circumference of Caliper Holder e Slide the groove of the caliper holder A through the stop B of the swingarm and install the rear caliper C to the holder Torque Caliper Mounting Bolts rear 2 5 N m 2 5 kgf m 18 ft lb e Adjust the drive chain after installation see Final Drive chapter e Tighten the rear axle nut to the specified torque Torque Rear Axle Nut 79 N m 8 1 kgf m 58 ft Ib e Insert a new cotter pin and bend it over the axle WHEELS TIRES 8 7 Wheels Rims e Check the rear brake A 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
59. 0607S1 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 e Check too see if the caliper holder shafts are not badly worn or stepped or the rubber boot is not damaged If the shafts or rubber boot are damaged replace the shafts rubber boot and the caliper holder BRAKES 10 11 Brake Pads Removal e When removing the rear brake pads take off the caliper guard and loosen the pad bolts A e Remove the caliper B with the hose installed see Caliper Removal e Remove the pad bolt Rear Caliper e Take the piston side pad from the caliper holder e Push the caliper holder C toward the piston and then remove the pad D from the caliper holder shaft Installation Notes e Push the caliper piston in by hand as far as it will go e Install the anti rattle spring e Install the piston side pad first and then install the remain ing pad OThe piston side pad A of the rear caliper has a wear protecting shim B Be careful not to mix it up with the other pad e Tighten Torque Brake Pad Bolts 18 N m 1 8 kgf m 13 ft lb Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib e Check the brake for good braking power no brake drag and no fluid
60. 1 Frame Table of Contents Exploded VIE EA al 13 2 SCA EE 13 3 Seat REMOVAal eerste ee aloes etal oad eect tate see ek eaten dota oak 13 3 ele UE TEE 13 3 SIDS COVERS A AR 13 4 Side Cover Hemoval nr 13 4 13 2 FRAME Exploded View 6002222BW4 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 1 Rear Frame Pipe O Apply Oil FRAME 13 3 Seat Seat Removal e Remove the seat bolts A e Move back B and swing open the seat C and then remove it Seat Installation e Slip the hooks A of the seat under the washer B on the fuel tank and the brace C e Tighten the seat bolts 13 4 FRAME Side Covers Side Cover Removal e Remove Seat Bolts A Side Cover Bolts B Side Covers ELECTRICAL SYSTEM 14 1 Electrical System Table of Contents Exploded EE 14 2 Wiring Diagram EE 14 3 OC IMG ALONG a EE Eege 14 4 Precautions and Safety Instructions mutcioniicn nad ia nee 14 5 e El EE ee 14 5 Electiical WN NIN DEE 14 6 Inspectie nas a a a a AE E A AA a Tiag 14 6 el e THING EE E ta 14 7 AQUSTMEN EE 14 7 Flywheel Magneto EE 14 8 Removal sisine i e mined is ti 14 8 A E 14 8 e ten EE 14 9 ellene E 14 11 Crankshaft Sensor Installation iria AEN 14 12 Crankshaft Sensor Air Gap Adiustment ANNER 14 12 Crankshaft Sensor Inspechon ek 14 12 Crankshaft Sensor Peak Voltage Inspechon EE 14 13
61. 1 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 T3 15 N m 1 5 kgfm 11 in lb R Replacement Parts T4 5 4 N m 0 55 kgf m 48 in lb T5 49 N m 5 0 kgf m 36 ft lb ENGINE BOTTOM END TRANSMISSION 7 3 Exploded View 6102188BW4 C 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 Nm 2 2 kgf m 16 ft lb G Apply grease L Apply a non permanent locking agent R Replacement parts EO Apply engine oil 7 4 ENGINE BOTTOM END TRANSMISSION Specifications Item Transmission Oil Engine Oil Grade Viscosity Oil Level Capacity Standard Service Limit API SG SH SJ SL or SM with JASO MA MAT or MA2 SAE10W 40 In middle of level gauge EE 0 65 L KX85 A1 A3 B1 B3 Sa KX100 D1 D3 0 70 L KX85 A4 B4 KX100 D4 Crankshaft Connecting Rod Connecting Rod Big End Radial Clearance Connecting Rod Big End Side Clearance Crankshaft Runout Transmission Shift Fork Ear Thickness Gear Shift Fork Groove Width Shift Fork Guide Pin Diameter Shift Drum Groove Width Special Tools Bearing Puller Adapter 57001 136 Outside Circlip Pliers 57001 144 Bearing Puller 57001 158 Crankcase Splitting Tool Assembly 57001 1098 Bearing Driver Set 57001 1129 Crankshaft Jig 57001 11
62. 1i 4 12 ENGINE TOP END Cylinder 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 14 034 mm 0 5528 0 5525 in Service Limit KX85 KX100 14 116 mm 0 5557 in Connecting Rod small End Inside Diameter Standard KX85 KX100 18 013 18 002 mm 0 7092 0 7087 in Service Limit KX85 KX100 18 060 mm 0 7110 in ENGINE TOP END 4 13 Exhaust Valve KIPS Removal e Remove Carburetor Cylinder Head Cylinder e Take out the screws A and remove the cover B e Pull the valve assembly A out e Unscrew the bolt A and remove the operating rod and the lever B Installation e Scrape out any carbon and clean the valves with a high flash point solvent e Check the following for sings of damage Exhaust Valve Assembly Oil Seal O rings lf necessary replace them with new ones e Apply a 2 stroke engine oil to the following Valve Operating Rod Journal Main Exhaust Valve Parts e Apply a high temperature grease to the oil seal lip on the operating rod e Install the operating rod A with the lever B e Apply a non permanent locking agent to the thread of ex haust valve lever mounting bolt e Torque Torque Exhaust Valve Lever Mounting Bolt C
63. 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 x 1 40 16 x 1 85 Telescopic fork 275 mm 10 8 in 1 12 GENERAL INFORMATION General Specifications Items KX100 D1 D5 D6F D9F 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 EU Europe Model 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 As OPERATION Eech 75 hn 12 5 hr 25 mn required ENGINE Clutch adjust e Clutch plates inspect t e R Throttle cable adjust e Spark plug clean regap t e R Air cleaner element clean e Air cleaner element replace When damaged Carburetor inspect adjust e Transmission oil change e Piston and piston ring clean inspect t e R Cylinder head cylinder inspect e Exhaust valves clean inspect e Silencer clean inspect t e Silencer packing change e Small end bearing inspect t e R Kick pedal and shift pedal clean o Exhaust pipe O ring r
64. 3 9 N m 0 40 kgf m 35 in Ib 4 14 ENGINE TOP END Exhaust Valve KIPS e Install the butterfly valve A on the holder B with a pin C e Install the pin D in the slide valve E carefully the direc tion of the brim F e Place the slide valve on the holder as shown e Install the valve assembly at fully opened condition into the cylinder e Turn the operating rod A holding the holder B by hand to check that the slide and butterfly valve move smoothly e Install the Exhaust Valve cover e Torque Torque Exhaust Valve Cover Mounting Bolts 5 2 N m 0 53 kgf m 46 in Ib ENGINE TOP END 4 15 Muffler Removal e Remove the left side cover and scoop e Remove the muffler mounting bolts A e Pull the muffler body to backward e Remove Louver Exhaust Pipe Mounting Bolt A Exhaust Pipe Mounting Springs B e Pull the muffler body out of the cylinder Installation e Scrape any carbon out of the muffler e Check the exhaust O rings A for signs of damage If necessary replace them with new ones Replace the exhaust gasket with new one Apply molybdenum disulfide grease around the exhaust O rings Torque Muffler Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Exhaust Pipe Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Muffler Baffle Change Replace the muffler baffle if exhaust noise becomes too loud or the engine performance drops e Remov
65. 3 mm 0 169 in Shift Fork Guide Pin Shift Drum Groove Wear Inspection e Measure the diameter of each shift fork guide pin A and measure the width of each shift drum groove B lf the guide pin on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in lf any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 6 05 6 20 mm 0 238 0 244 in Service Limit 6 3 mm 0 248 in Gear Dog Gear Dog Hole Damage Inspection e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes Ball Bearing Wear Inspection e Check the ball bearing on the crankcase OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement OOil the bearing with transmission oil and spin A it by hand to check its condition If the bearing is noisy does not spin smoothly or has any rough spots replace it 6113004BS1i 6113014981 WHEELS TIRES 8 1 Wheels Tires Table of Contents Exploded RE 8 2 Specificato nr hth Saeed aceite e lara eis aside Agee as 8 3 Wheels RIMS EE 8 5 Front Wheel Removal usina ie 8 5 Front Wheel installati n re dota ita cios 8 5 Re
66. 4 N m 0 55 kgf m 48 in Ib e Install the advancer in the right engine cover GRO4010BS1 GRO4011BS1 GRO4012BS1 6R04014BS1 ENGINE RIGHT SIDE 5 13 Clutch Removal e Remove the clutch cover e Remove the magneto cover e Unscrew the crankshaft sensor mounting screws and re move the crankshaft sensor B from the stator e Install the flywheel holder A on the magneto flywheel NOTE OUse the flywheel holder to prevent the clutch from rotat ing Special Tool Flywheel Holder 57001 1313 e Remove the clutch spring bolts A spring and clutch pressure plate e Remove the ball bearing push rod A shim B if pro vided friction plates and steel plates e Remove the clutch hub nut A and washer NOTE OUse the clutch holder B to prevent the clutch hub from rotating Special Tool Clutch Holder 57001 1243 e Remove the clutch assembly needle bearings A sleeve B and thrust washer C GRO50604S1 5 14 ENGINE RIGHT SIDE Clutch Installation Notes e Apply molybdenum disulfide grease to the outside of the sleeve e Apply transmission oil to the inside of the clutch housing gear and Kickstarter driven gear e Install the friction plates and steel plates starting with a friction plate and alternating them Finish with a friction plate Do not install dry steel plates and fricti
67. 49M E DUNLOP D737 DUNLOP D756 DUNLOP D752 EU 17 x 1 40 14 x 1 60 B1 B4 B5 B6F 70 100 19 70 100 19 42M 70 100 19 42M EU BRIDGESTONE M61 DUNLOP D752F EU 90 100 16 90 100 16 52M EU BRIDGESTONE M58 BRIDGESTONE M401 ES DUNLOP D756F EU 90 100 16 52M BRIDGESTONE M402 DUNLOP D752 EU DUNLOP D756 EU 19 x 1 40 16 x 1 85 D1 D4 D5 D6F 70 100 19 70 100 19 42M 70 100 19 42M EU BRIDGESTONE M61 DUNLOP D752F EU 90 100 16 90 100 16 52M EU BRIDGESTONE M58 DUNLOP D752 EU BRIDGESTONE M401 90 100 16 52M BRIDGESTONE M402 8 4 WHEELS TIRES Specifications Service Limit Standard Di D4 Rim Size Front a Rear e EU Europe Model A WARNING Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death To ensure proper handling and stability use only the recommended standard tires for replacement inflated to the standard pressure Special Tools Inside Circlip Pliers 57001 143 Rim Protector 57001 1063 Bead Breaker Assembly 57001 1072 Bearing Driver Set 57001 1129 Jack 57001 1238 Bearing Remover Shaft 9 57001 1265 Bearing Remover Head 10 x 612 57001 1266 WHEELS TIRES 8 5 Wheels Rims Front Wheel Removal e Remove the following Cotter Pin A Axle Nut B e Using the jack A and a stand B raise the front whee
68. 74 0 023 0 035 mm 0 08 mm 0 35 0 45 mm 0 7 mm TIR 0 03 mm or less TIR 0 08 mm 3 9 4 0 mm 3 8 mm 4 05 4 15 mm 4 3 mm 5 9 6 0 mm 5 8 mm 6 05 6 20 mm 6 3 mm Sealant Liquid Gasket TB1105B 92104 002 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 A 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 Check the oil level be fore each use and change the oil and filter accord ing to the periodic maintenance chart Oil Level Inspection e Situate the motorcycle so that it is perpendicular to the ground elt the motorcycle has just been used wait several minutes until the oil settles e Check that the oil level comes up in the middle A of the oil level gauge B on the right engine cover lf the oil level is too high remove the excess oil through the oil filler opening C using a syringe or some other suitable device lf the oil level is too low add the correct amount of oil Use the same type and make of oil that is already in the engine 6117060281 NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top up the level in preference to
69. 85 B3 EE or KX100D8F JKAKXTDCO8A023001 JKBKXFACOI9A045001 or JKAKXTDCO3A008001 or KX85A9F IKBKX085AAA045001 2003 KX100 D3 JKAKS100DDA008001 JKBKXFBCO9A025001 or 2004 KX85 A4 JKBKXFACO4A021001 2009 KX85B9F JKBKX085BBA025001 2004 KX85 B4 D EN or 2009 KX100D9F JKAKXTDCO9A026001 JKBKXFACOAA049001 or JKAKXTDCO4A012001 or 2010 KX85AAF JKBKX085AAA049001 2004 KX100 D4 JKAKX100DDA012001 SE Sep Kxgspar KBKXFBCOAAO28001 or A O or JKBKX085BBA028001 2005 KXBSAS JKBKX085AAA026001 JKBKXFBCO5A012001 or 2005 KX85 B5 JKBKX085BBA012001 2005 KX100 D5 JKAKXTDCO5A015001 O This digit in the frame number changes from one machine to another WE Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1265 10 Printed in Japan
70. A WARNING The shock contains high pressure nitrogen gas that when suddenly released can eject oil and internal shock parts at high velocity causing serious injury To avoid injury do not point the reservoir valve to ward your face or body when releasing nitrogen gas pressure since an oil mist is often released with the nitrogen Always release nitrogen gas pressure be fore disassembling the rear shock absorber to pre vent explosive separation of parts GM050619S1 e Adjust the compression damping adjuster on the gas reservoir to the softest position e Remove the air bleeder bolt A and pump the rear shock to drain the oil out of the rear shock body e Pry A at the gaps B in the stop C with suitable tools to free the stop from the rear shock body D e Slide the stop up the top of the push rod then lightly tap around the seal with a suitable rod and mallet and push the seal assembly 10 mm 0 04 in down e Remove the circlip A e Lightly move the push rod back and forth and pull out the push rod assembly e Pour the remaining oil out of the rear shock body 11 18 SUSPENSION Rear Shock Absorber Oil Filling e Check the O ring on the air bleeder bolt and replace it if necessary e Install the air bleeder bolt e 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 Rear Shock
71. Absorber e 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 OThe bladder B comes out with the gas reservoir cap Assembly e Check that the bladder A on the gas reservoir cap is not partially collapsed e If it is push down the valve core with a screwdriver e Check the bladder for sign of damage or crack If neces sary replace it with a new one NOTICE Do not use a damaged or partially collapsed blad der because it may burst gently reducing rear shock performance e Apply grease to the lip B of the bladder e Push the bladder and gas reservoir cap into the gas reser voir slowly until it just clears the circlip groove Wipe out any spilled oil NOTICE Ensure that no air remains in the system e Check the circlip for weakening deformity and flaws If necessary replace it with a new one A WARNING Pressurized nitrogen gas can explode out of the shock reservoir cap if a weakened deformed or flawed circlip is used allowing oil and internal parts to burst out of the reservoir with great force and cause serious injury To avoid injury always use a new circlip whenever the shock is reassembled e Fit the circlip A in the groove in the gas reservoir B SUSPENSION 11 21 Rear Shock Absorber e Pull up the gas reservoir cap A against the circlip The end B of
72. B Roller C Pin D Pin Link E Roller Link GKO4011BS1 e Stretch the chain taut by hanging a 10 kg 20 lb weight O A on the chain e Measure the length of 20 links B on the straight part C of the chain from the pin center of the 1st pin to the pin center of the 21st pin Since the chain may wear unevenly take O measurements at several places Drive Chain 20 link Length Standard 254 0 mm 10 0 in Service Limit 259 mm 10 2 in 6K04060651 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 A 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 Inspect the chain for damage and proper adjustment before each ride If chain wear exceeds the service limit replace it with the standard chain Lubrication e lf the chain appears especially dirty it should be cleaned with high flash point solvent before lubricating e f a special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings A Oil Applied Areas e Wipe off any exces
73. C 31 Total amount 0 67 L 0 71 US qt NOTE OChoose a suitable mixture ratio by referring to the coolant manufactures directions e Install the drain plug OReplace the gasket with a new one Torque Coolant Drain Plug Water Pump 5 4 N m 0 55 kgf m 48 in Ib Coolant Drain Plug Cylinder 8 8 N m 0 90 kgf m 78 in Ib e Fill the radiator up to the filler neck with coolant Breather Hose A Coolant Level B Filler Neck C NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator 6D07008BSi e Bleed the air from the cooling system as follows OLoosen the air bleeder bolt A on the cylinder head B until the coolant begins to flow out the air bleeder bolt hole that is until all the remaining air has been forced out OTighten the air bleeder bolt OStart the engine with the radiator cap removed and run it until no more air bubbles A can be seen in the coolant OTap the cooling hoses to force any air bubbles caught inside OStop the engine and add coolant up to the filler neck e Check the cooling system for leaks e Install the radiator cap OThe radiator cap must be installed in two steps First turn the cap clockwise to the first stop Then push down on it and turn it the rest of the way GDO50109S1 3 8 COOLING SYSTEM Coolant Cooling System Pressure Testing Any time the system slowly loses coolant inspect for l
74. E Ne 3 9 Impeller SEH eege eege ee degen 3 9 Water Pump Shaft Removal rt lit tated tt eed 3 10 Water Pump Seal REMOV EE 3 10 Water Pump Seal Installation sac ad dotada Canes Gees 3 10 Ree EE 3 11 Radiator Removal at Eege ee 3 11 Radiator installato A io ee 3 11 Radiator InspeCcuO caniaii aeaa aaa Aaa ladito eli 3 11 GIG ANG E 3 11 Radiator Cap een acca afc ii pte ae aaa ee aes 3 12 Filler Neck Inspection eiii a 3 12 Water Hoses Connections Inspechon nn nnnnnre erenn 3 12 Water Hoses Breather Hose jnstallatton 3 12 3 2 COOLING SYSTEM Exploded View 6D02077BW4 C 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 mb 4 Water Pump Cover T4 5 4 N m 0 55 kgf m 48 mb 5 Impeller M Apply molybdenum disulfide grease 6 Water Pump Bearing R Replacement Parts 7 Water Pump Seal 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 ch dl sch Sou A CH SE EENEG il UTN SKIL AAA WWW Sy N Y 7 i O O e OI CH 3 al TEY o 7 Crankshaft Water Pump Drive Gear Primary Gear Water
75. Pump Shaft Gear Impeller Water Pump Cover Joint Water Hose Cylinder Cylinder Head Upper Water Hose Radiator Cap Breather Hose Radiator Lower Water Hose 6D04080283 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 Total Capacity 0 67 L 0 71 US qt Radiator Cap Relief Pressure 93 123 kPa 0 95 1 25 kgf cm 14 18 psi Special Tool Bearing Driver Set 57001 1129 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 A 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 Wait until it cools down Coolant Level Inspection e Situate the motorcycle so that it is perpendicular to the ground NOTE ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap A e The coola
76. able Compression Pressure Usable Range 825 1 280 kPa 8 4 13 0 kgf cm 119 185 psi If compression pressure is higher than the usable range check the following Carbon build up on the piston head and cylinder head clean off any carbon on the piston head and cylinder head Cylinder head gasket cylinder base gasket use only the proper gaskets for the cylinder head and base The use of gasket of the incorrect thickness will change the pressure e lf compression pressure is lower than the usable range check the following Piston cylinder clearance piston seizure Gas leakage around the cylinder head replace the dam aged gasket and check the cylinder head for warp Piston ring piston ring groove clearance Removal e Remove the following Radiators see Cooling System chapter Muffler see Muffler Removal Spark Plug Cooling Hose Lower End Engine Bracket Bolts and Nuts e Remove the cylinder head nuts A and take off the cylin der head B and gasket C GE05050181 ENGINE TOP END 4 5 Cylinder Head Installation e Replace the head gasket with a new one e Scrape out any carbon and clean the head with a high flash point solvent e Check the head water jacket for a crust of minerals and rust and remove them if necessary e Install a new cylinder head gasket with the side marked UP A facing up e Torque Torque Engine Bracket Nuts 29 N m 3 0 kgf m 22 ft lb Cylinder Head N
77. age OTo install the plug cap turn it clockwise Ce 6P10199BS1 6P100107S1 ELECTRICAL SYSTEM 14 15 Ignition System KX85A6F B6F KX100D6F C Spark Plug Cleaning and Inspection e Remove the spark plug and visually inspect it e 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 l the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug Spark Plug Gap Inspection e Measure the gap A with a wire type thickness gauge lf the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 7 0 8 mm 0 028 0 031 in CDI Unit Inspection Ignition Coil Primary Peak Voltage Check NOTICE When inspecting the CDI Unit observe the follow ing to avoid damage to the CDI Unit Do not disconnect the CDI Unit while the engine is running This may damage the CDI Unit e Remove the spark plug cap but do not remove the spark plug e Install new spark plug into the spark plug cap and ground it onto the engine 6P10197BS1 C GP100619S1 14 16 ELECTRICAL SYSTEM Ignition System e Install the peak voltage Adapter A into the Hand T
78. amaged the piston must be replaced and fitted with new rings e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to the groove sur faces If not the piston must be replaced With the piston ring in its groove make several mea surements with a thickness gauge A to determine piston ring groove clearance xX lf the clearance exceeds the service limit measure the thickness of the piston ring If the ring has worn down to less than the service limit replace the ring if the groove width exceeds the service limit replace the piston Piston Ring Groove Clearance Standard Top KX85A B 0 020 0 060 mm 0 0008 0 0024 in KX100D 0 040 0 080 mm 0 0016 0 0032 in Second 0 020 0 060 mm 0 0008 0 0390 in Service Limit Top KX85A B 0 16 mm 0 0063 in KX100D 0 18 mm 0 0071 in Second 0 16 mm 0 0063 in Piston Ring Thickness Top and Second Standard 0 97 0 99 mm 0 0382 0 0390 in Service Limit 0 90 mm 0 0354 in 6E16020851 ENGINE TOP END 4 11 Cylinder Piston Ring Groove Width Standard Top KX85A B 1 01 1 03 mm 0 0398 0 0406 in KX100D 1 03 1 05 mm 0 0406 0 0413 in Second 1 01 1 03 mm 0 0398 0 0406 in Service Limit Top KX85A B 1 11 mm 0 0437 in KX100D 1 13 mm 0 0445 in Second 1 11 mm 0 0437 in Piston Ring End Gap Inspection e Place the piston ring A inside the cylinder
79. ansmission Shaft Installation e Set the transmission shafts shift drum and shift forks together and fit them into the right crankcase half OApply transmission oil liberally to the transmission gears bearings shaft journals and shift fork fingers OFit each shift fork into the groove of the proper gear so that the shift fork guide pin is in the proper groove on the shift drum A Shorter Shift Fork Drive Shaft B Left Shift Fork Output Shaft C Longer Shift Rod Output Shaft D Shift Drum E Shorter Shift Rod Drive Shaft F Right Shift Fork Output Shaft e Apply small amount of engine oil to the shift rods and install the rods Torque Output Shaft Bearing Retaining Screws 5 4 N m 0 55 kgf m 48 in Ib Drive Shaft Bearing Retaining Bolts 8 8 N m 0 90 kgf m 78 in Ib NOTE OBe careful not to confuse the shift forks or the shift rods e Assemble the crankcase see Crankcase Assembly Transmission Shaft Disassembly e Remove the transmission shafts see Transmission Shaft Removal e Using the outside circlip pliers remove the circlips and disassemble the transmission shafts completely Special Tools Outside Circlip Pliers 57001 144 Transmission Shaft Assembly e Apply engine oil liberally to the transmission shaft gears and bearings e Install a new circlip on the drive shaft so that opening coincides with one of the spline grooves in the shaft OBe careful not to install the gears backwards
80. ar Wheel Removal 8 6 Rear Wheel perseun sign ag engt Ee ege 8 6 Wheels Ee EE 8 7 Spoke Inspection 8 7 A ousand eomapattan T TS 8 7 Axle WS DS CU e 8 8 A tee ee aere 8 9 o O 8 9 A EE 8 10 Air Pressure Inspection AdjUStIMeNt oooooooicccccnononnnnonncccnncnnononnnnncccnnnnn ranma rn 8 10 Eo A AA y Soe ERANT EDA AA CaA edo Eain 8 11 Hub Bearing Wheel B artpmgek sg cidssdet ciecaesiages SEBES Age del ENEE EES ees 8 12 Removal EE 8 12 Installation cata 8 12 e 8 12 EDIC O O ad 8 12 8 2 WHEELS TIRES Exploded View GJ02095BW4 C 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 WHEELS TIRES 8 3 Specifications Item Standard Service Limit Wheels Rim Runout with tire installed Axial Radial Axle Runout 100 mm 3 94 in TIR 1 0 mm 0 04 in or less TIR 0 10 mm 0 004 in or less TIR 2 mm 0 08 in TIR 0 2 mm 0 008 in Tires Air Pressure Front and Rear 98 kPa 1 0 kgf cm 14 psi Eguna Standard Tires Rims KX85A Front Size Make Type Rear Size Make Type Rim Size Front Rear KX85B Front Size Make Type Rear Size Make Type Rim Size Front Rear KX100D Front Size Make Type Rear Size Make Type A1 A5 A6F 70 100 17 40M E DUNLOP D737F DUNLOP D756F DUNLOP D752F EU 90 100 14
81. asurement 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 KX100D 52 435 52 450 mm 2 0644 2 0650 in Service Limit KX85A B 48 29 mm 1 9012 in KX100D 52 29 mm 2 0587 in Piston Cylinder Clearance Inspection The piston to cylinder clearance is measured whenever a piston or cylinder is replaced with a new one The standard piston to cylinder clearance must be adhered to whenever the cylinder is replaced If only a piston is replaced the clearance may exceed the standard slightly But it must not be less than the minimum in order to avoid piston seizure 6E060103S1i 4 10 ENGINE TOP END Cylinder The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measure ments and then computing the difference between the two values 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 0 075 mm 0 0026 0 0030 in Piston Ring Piston Ring Groove Inspection e Visually inspect the piston rings and the piston ring grooves If the rings are worn unevenly or damaged they must be replaced x If the piston ring grooves are worn unevenly or d
82. ath the carburetor e Turn the fuel tap to the OFF position e 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 e Install the drain plug securely Removal A 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 this includes any appliance with a pilot light e Turn the fuel tap to the OFF position and pull the fuel hose off e Screw in the upper and lower throttle cable adjusters to give the cable plenty of play see Throttle Cable Adjust ment e Loosen the clamps and remove the carburetor from the end of the air cleaner duct and then pull it out of the carburetor holder to the vehicle left side e Remove the throttle grip to make a play on the throttle cable enoughly e Remove the carburetor cap screws and pull out the throt tle valve assembly A NOTICE If the throttle valve is not removed from the cable wrap it in a clean cloth to avoid damage e After removing the carburetor push a clean lint free towel into the carburetor holder and the air cleaner duct to keep dirt or other foreign material from entering A WARNING If dirt or
83. b ENGINE BOTTOM END TRANSMISSION 7 11 Crankshaft Connecting Rod e Push the connecting rod first towards the gauge and then Connecting Rod Big End Radial Clearance in the opposite direction The difference between the two gauge readings is the radial clearance Inspection x lf the radial clearance exceeds the service limit the crank e Set the crankshaft in a flywheel alignment jig or on V blocks and place a dial gauge against the connecting rod shaft should be either replaced or disassembled and the E crankpin needle bearing and connecting rod big end ex big end amined for wear Connecting Rod Big End Radial Clearance Standard 0 029 0 041 mm 0 0011 0 0016 in Service Limit 0 09 mm 0 0035 in Connecting Rod Big End Side Clearance Inspection e Set the crankshaft on V blocks e Measure the side clearance A of the connecting rod with a thickness gauge lf the clearance exceeds the service limit replace the crankshaft Connecting Rod Big End Side Clearance Standard 0 40 0 50 mm 0 016 0 20 in Service Limit 0 7 mm 0 028 in GIO5006BS1 Crankshaft Runout Inspection e Set the crankshaft on V blocks and place a dial gauge against the points indicated e Turn the crankshaft slowly The maximum difference in gauge readings is the crankshaft runout Crankshaft Runout Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 08 mm 0 0031 in
84. bearings blow any dirt or for eign particles out of the hub with compressed air to pre vent contamination of the bearings e Install the bearings A by using the bearing driver set B which does not contact the bearing inner race Special Tool Bearing Driver Set 57001 1129 NOTE Olnstall the bearings so that the marked side or the sealed side faces out Inspection Since the hub bearings are made to extremely close tol erances the clearance cannot normally be measured e Turn each bearing back and forth A while checking for roughness or binding If roughness or binding is found replace the bearing e Examine the bearing seal B for damage or leakage lf the seal is damaged or is leaking replace the bearing Lubrication NOTE OSince the hub bearings are packed with grease and sealed they are not required to be removed for lubri cation 6J06060451 6yJ060101S1 6J06002BS1 FINAL DRIVE 9 1 Final Drive Table of Contents Exploded Mi Wii dit 9 2 o Eeer e geg eh advsausue dedae Gas euE ORES 9 3 Drive CHAIN EE 9 4 A nesa e e e a aE E E T ES 9 4 Wheel Alignment AdjustMent occoconoccnanonoccconononnnnnnncnnnncnnnnnnnnnccccnnnn nn rre 9 5 Wear Inspection E 9 5 CUBANO DE 9 6 MOV ias 9 6 URS AMATO ce tes eege eege Eege ee 9 6 lee GIS aah secs add ate settee aes ss SR ORNS ed et aor aac 9 7 Engine Sprocket Removal EE 9 7 Engine Sprocket Installation
85. ca 12 4 EE A eared A di Orde aaa eras Gh 12 5 e UE EE 12 5 Steering SUSI EE EE 12 6 Removal 12 6 O EEe E E E 12 6 Bearing Seal Deterioration Damage Inspection 12 6 Steering Stem Warp Inspection ost anti pas 12 7 Steering Stem Bearing isidro aden ne 12 8 REMOVAL EE 12 8 Installation EE 12 8 CUBA o es ce ondo 12 9 Wear Damage a e e RE 12 9 12 2 STEERING Exploded View GNO20605W4 C T3 20 N m 2 0 kgf m 15 ft lb T4 Hand tight or 4 9 N m T2 64 N m 6 5 kgf m 47 ft lb AD Apply adhesive T1 25 N m 2 5 kgf m 18 ft lb 0 49 kgf m 43 in lb G Apply grease O Apply oil STEERING 12 3 Specifications Special Tools Bearing Driver 632 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 gt 37 mm 57001 1107 Jack 57001 1238 12 4 STEERING Handlebar Installation e Install the handlebar holders so that the arrow A on the holder points to the front e Align the punch mark D on the handlebar to the mating surface of each clamps of handlebar front master cylin der e Tighten the front holder bolts B first and then the rear holder bolts to the specified torque There will be a gap C at the rear part of the holder after tightening Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft Ib
86. cacon iaa ade 9 7 Rear Sprocket Removal Ee Eege 9 7 Rear Sprocket Installation coin aia das 9 7 Spro ket WO Arras id aia 9 7 Rear Sprocket Wa Pinnacle da da 9 2 FINAL DRIVE Exploded View GK02123BW4 C 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 L Apply a non permanent locking agent R Replacement parts FINAL DRIVE 9 3 Specifications Special Tools Outside Circlip Pliers 57001 144 Jack 57001 1238 Item Standard Service Limit Drive Chain Make and Type Daido DID 420DS2 Joint Endless KX85A 120 links KX85B KX100 D 124 links Chain Slack 54 64 mm 2 13 2 52 in 20 link Length 254 0 mm 10 0 in 259 mm 10 2 in Sprockets Rear Sprocket Warp TIR 0 4 mm or less TIR 0 5 mm 9 4 FINAL DRIVE Drive Chain Slack Adjustment e Set the motorcycle up on its side stand e Check to see that the notches A on the alignment indi cators B on both sides are in the same relative position C x If they are not adjust the chain slack and align them A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Be sure the wheel is properly aligned NOTE OClean the drive chain if it is dirty and lubricate it if it appears dry e Turn th
87. cket Fuel Tank Breather Hose Assy and install the check valve of arrow mark direction to fuel tank cap side Insert the fuel tank breather hose outlet end into the number Plate hole Band KX85A6F B6F KX100D6F KX85A6F B6F KX100D6F 1 24 GENERAL INFORMATION Cable Wire and Hose Routing 6B09117CW4 C 1 Engine Stop Button Ground Lead B Run the engine stop button lead through N the clamp for throttle cable Engine Stop Button Lead BK W CDI Unit CDI Unit Ground Lead BK Y CDI Unit Primary Lead O Bands Clamp CDI unit Installation Bolts ch CDI Unit Lead to Engine Stop Button BK 11 12 13 14 15 16 17 Ignition Coil Ignition Coil Primary Lead Bundle the harness under the frame pipe Fit the taping part of harness with band so that there is not a loose or tension of har ness between the connector and band Engine Stop Button Lead BK W BK CDI Unit Ground Lead BK O CDI Unit Lead to Engine Stop Button BK BK Y KX85A6F B6F KX100D6F Cable Wire and Hose Routing GENERAL INFORMATION 1 25 6B09810BW4 C k N POOL OO Tighten the CDI unit and engine stop but ton ground terminals together with lower ignition coil installation bolt Install the ignition coil so that the ignition secondary coil come to backward Ignition Coil Installation Bolts Radiator Carburetor Magneto Cover Run the carburet
88. clamp after tightening Torque Front Master Cylinder Clamp Bolts 8 8 N m 0 9 kgf m 78 in Ib e Use a new flat washer on each side of the brake hose fitting e Tighten the banjo bolts to the specified torque Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft lb Rear Master Cylinder Removal e Drain the rear brake fluid see Brake Fluid Change e Loosen the banjo bolt A e Remove the following Reservoir Mounting Bolt Brake Pedal Joint Pin B Upper End of Brake Hose Banjo Bolt and Brake Hose Rear Master Cylinder Mounting Screws C e Remove the master cylinder D Rear Master Cylinder Installation Notes e Use a new flat washer on each side of the brake hose fitting e Tighten the banjo bolts to the specified torque Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Tighten the rear master cylinder mounting screws 2 to the specified torque Torque Rear Master Cylinder Mounting Screws 9 8 N m 1 0 kgf m 87 in Ib Rear Brake Reservoir Bolt 5 9 N m 0 60 kgf m 52 in Ib GLO70602S1 GLO7O0603S1 10 14 BRAKES Master Cylinder Inspection and Adjustment after Installation e Fill the brake line with the brake fluid see Brake Fluid Change e Check and adjust the following items after installation Brake Pedal Position Brake Line Air Bleed Brake Drag Braking Power Brake Fluid Leakage A WARNING After servicing it takes several applications of the b
89. ct e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system after the coolant cools down e Fill the system with fresh water e Warm up the engine and drain the system after the coolant cools down e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Coolant Bleeding GD05060281 COOLING SYSTEM 3 9 Water Pump Water Pump Cover Removal e Drain the coolant see Coolant Draining e Loosen the cooling hose clamps and disconnect the cool ing hoses A on the water pump cover e Remove the water pump cover bolts B and remove the water pump cover C Water Pump Cover Installation e Fill the cooling system see Coolant Filling Impeller Removal e Drain the coolant see Coolant Draining e Remove the cover bolts and take out the water pump cover from the right engine cover with the cooling hoses attached e Remove the impeller bolt A and pull out the impeller B Impeller Installation e Install the following Washer A Impeller B Impeller Bolt C e Torque the impeller bolt Torque Water Pump Impeller Bolt 7 0 N m 0 70 kgf m 61 in Ib Impeller Inspection e Check the impeller A visually lf the corrosium or damage on the impeller replace it 6D060602S1 3 10 COOLING SYSTEM Wat
90. damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change lf the idle speed increase check the throttle cable free play and the cable routing Free Play Adjustment e Loosen the locknut A at the upper end of the throttle cable e Turn the adjuster B until the proper amount of throttle grip free play is obtained e Tighten the locknut lf the throttle grip free play cannot be adjusted with the adjuster at the upper end of the throttle cable use the cable adjuster A at the carburetor e Pull the boot off of the carburetor top e Loosen the locknut and turn the adjuster until the proper amount of throttle grip play is obtained e Tighten the locknut B e Slide back the dust cover e Turn the handlebar from side to side while idling the en gine If idle speed varies the throttle cable may be poorly routed or it may be damaged A WARNING Operation with improperly adjusted incorrectly routed or damaged cables could result in an unsafe riding condition Follow the service manual to be make sure to correct any of these conditions 6C040601S1 6604060351 2 6 FUEL SYSTEM Throttle Grip and Cable Installation Notes e Install the throttle cable in accordance with the Cable Wire and Hose Routing section in the General Informa tion chapter
91. drained easily e Place a container under the coolant drain plug Water Pump A e Drain the coolant from the radiator and engine by remov ing the drain plug at the bottom of the water pump e Remove the radiator cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap e The coolant will drain from the radiator and engine e Place a container under the drain plug on the right side of the cylinder and drain the coolant by removing the drain plug Cylinder A e Inspect the oil coolant for visual evidence of corrosion and abnormal smell see Coolant Deterioration Inspection Coolant Filling Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac ture s Soft or distilled water must be used with the antifreeze see below for antifreeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages and considerably reduces the efficiency of the cooling system 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
92. e C facing out see above photo e Install the right engine cover see Right Engine Cover In stallation Primary Gear Removal KX85A6F B6F KX100D6F e Remove the right engine cover see Right Engine Cover e Remove the clutch see Clutch Removal e Temporarily install the clutch housing A e Using the gear holder B secure the primary gear Special Tool Gear Holder 57001 1602 e Remove the clutch housing e Remove the primary gear nut C washer and the primary gear D OPrimary gear nut is left hand threads Primary Gear Installation KX85A6F B6F KX100D6F e Apply high temperature grease to the kick pedal shaft oil seal lip e Insert the primary gear A to the crankshaft e Install Washer B Primary Gear Nut C e Install the spring washer A with the concave side facing to the inward e Temporally tighten the primary gear nut B 6RO60601S1 6F15000BS1 ENGINE RIGHT SIDE 5 17 Primary Gear e Using the gear holder A secure the clutch gear and the bottom of the primary gear then tighten the primary gear nut B OPrimary gear nut is left hand threads Torque Primary Gear Nut 49 N m 5 0 kgf m 36 ft Ib Special Tool Gear Holder 57001 1602 e Install Clutch see Clutch Installation 5 18 ENGINE RIGHT SIDE External Shift Mechanism Removal e Remove the following Brake Pedal see Brakes chapter Magneto
93. e Drain the fork oil see Fork Oil Level Adjustment e Remove the following Push Rod Nut Spring Guide lt Cylinder Unit Removal gt e Hold the fork leg horizontally in a vise e Compress the outer tube e Stop the cylinder unit A from turning by using the fork cylinder holder B Unscrew the cylinder valve assembly C and take the cylinder valve assembly and gasket D out of the bottom of the inner tube E Special Tool Fork Cylinder Holder 57001 1413 e Remove the push rod A and cylinder unit B from the top of the outer tube C 6M04011351 6M04061351 SUSPENSION 11 11 Front Fork lt Inner Tube Removal gt e Separate the inner tube A from the outer tube B as follows OSlide up the spring band C A OSlide up the dust seal D 6M040614S1i ORemove the retaining ring B from the outer tube A 6M040156S1 OGrasp the outer tube and stroke the inner tube up and down several times The shock to the fork seal separates the inner tube from the outer tube lf the tubes are tight use the special tool A Special Tool Fork Outer Tube Weight 57001 1218 GM040622S1 e Remove the guide bushes A washer B oil seal C retaining ring D dust seal E from the inner tube Assembly each fork leg e Assembly is the reverse of disassembly lt Inner Tube Assembly gt e Replace the following parts removed with a
94. e mating surfaces of right engine cover and clutch cover e Replace the clutch cover gasket with a new one e Torque Torque Clutch Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib 6R1206018S1 ENGINE RIGHT SIDE 5 9 Right Engine Cover Right Engine Cover Removal e Remove Engine Oil drain Coolant drain Cooling Hose Lower End Kick Pedal Brake Pedal Water Pump Cover Impeller Clutch Cable e Remove the KIPS cover from the right side of the cylinder e Remove the E clip A e Put a spanner wrench A on the shaft lever upper end e Turn the shaft lever counterclockwise with the wrench and separate the link lever B from the lever pin KX85 A4 B4 KX100 D4 e Remove the KIPS cover from the cylinder right side e Remove the E ring G e Remove the lever assy mounting screw B washer C lever assy D collar E and spring F from the lever shaft A GRO4013BS1 5 10 ENGINE RIGHT SIDE Right Engine Cover e Remove the right engine cover bolts A and take off the right engine cover B and gasket Cover Installation e There are two knock pins of the mating surfaces of the crankcase and right engine cover e Apply molybdenum disulfide grease A to the water pump shaft B to prevent water pump seal damage NOTICE If the right engine cover is installed without greas ing the pump shaft the pump seal could damage e Turn the clutch release lever t
95. e off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Motor Oil Clutch Lever Brake Lever Kick Pedal Shift Pedal Rear Brake Rod Joint Drive Chain Points Lubricate with Grease A Clutch Inner Cable Upper and Lower Ends Throttle Inner Cable Upper Ends SwingArm Pivot Tie Rod Pivot RockerArm Pivot Steering Stem Bearing 6c040101S1 Cables Lubricate with Rust Inhibitor Throttle Cables Clutch Cable 6004011481 e With the cable disconnected at both ends the cable should move freely A within the cable housing If cable movement is not free after lubricating if the cable is frayed or if the cable housing is kinked replace the cable D 6004040251 APPENDIX 15 7 Bolt Nut and Fastener Tightness Bolt Nut and Fastener Tightness Tightness Inspection e 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 OFor the engine fasteners check the tightness of them when the engine is cold at room temperature lf there are loose fasteners retorque them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque spec
96. e rear wheel to find the position where the chain is tightest e Measure the vertical movement midway between the sprockets x If the drive chain slack A exceeds the standard adjust it as follows Chain Slack Standard 54 64 mm 2 13 2 52 in NOTE Oln wet any muddy conditions mud sticks to the chain and sprockets resulting in an overly right chain and the chain may break e Loosen the left and right chain adjuster locknuts C e Remove the cotter pin F and loosen the axle nut A lf the chain is too tight back out the left and right chain adjusting bolts B evenly and kick the wheel forward until the chain is too loose If the chain is too loose turn both chain adjusting bolts evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch E on the right chain adjuster should align with the same swingarm mark D as the left chain adjuster notch aligned with e Check the wheel alignment e Tighten the axle nut Torque Rear Axle Nut 79 N m 8 1 kgf m 58 ft Ib e Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary e Install a new cotter pin through the axle nut and axle and spread its ends A WARNING A loose axle nut can lead to an accident resulting in serious injury or death Tighten the axle nut to the proper torque and install a new cotter pin IS Or NE
97. e so that the front wheel off the ground Special Tool Jack 57001 1238 e Clean the bottom of the fork tubes e Remove the caps on the bottom of the fork tubes e To adjust compression damping turn the adjuster A on the front fork cylinder valve with the blade of a screwdriver until you feel a click Adjust the compression damping to suit your preference under special condition NOTE OThe left and right fork legs must have the same shock damping Compression Damping Adjuster Setting Standard KX85A 8 clicks KX85B KX100D 6 clicks Seated positions adjuster turned fully clockwise A Harder B Softer C e Put the caps into the bottom of the fork tubes Fork Oil Level Adjustment each fork leg lt Draining Oil gt e Loosen the fork top plug temporarily e Remove the front fork e Hold the fork leg vertically in a vise e Remove the fork top plug from the outer tube e Compress the outer tube e Press the fork spring A away from the top plug and slip the fork spring holder B in on top of the spring seat and under the push rod nut C Special Tool Fork Spring Holder 57001 1286 GMO40609S1 6M04008BS1i 0 Number of turns counterclockwise usable range 16 clicks 6M040578S1 6M040610S1 11 6 SUSPENSION Front Fork e Use wretches on the rod nut and the top plug A to loosen the rod nut e Remove the top plug from the
98. e the muffler pipe and inner pipe mounting bolts A and pull the inner pipe out toward the rear e Pull off the old muffler baffle B and wrap new muffler baffle around the inner pipe e Install inner pipe into the muffler body 6E080601Si ENGINE RIGHT SIDE 5 1 Engine Right Side Table of Contents Exploded In Genee eet eege Eege deg 5 2 Ee 5 4 OMNES TN A Sancta ar deat ace Dead Maden 5 5 Clutch Cable Free Play Inspection ica ct 5 5 Clutch Cable Fres Play AQUStimMe osito 5 5 Clutch Release Lever Angle Inspection and Adiustment 5 6 ROMO or A ds Installato m eana aa tee stee cena bash an tt oad tead dace ate tanta eed Coen a Lubrication and Inspection taa A A A O A E en mee err EE Ort ieee Clutch Cover Removal asco sccses cist e a e SEENEN Clutch Cover Installation BEE eessen ege 5 8 RIGHT Engine Gover EE 5 9 Right Engine Cover REMOV EE 5 9 Cover Installaatio EEN 5 10 Right Engine Cover Disassembly EE 5 11 Advancer Disassembly EE 5 11 e eegne EE 5 12 Right Ge ee E une 5 12 leede enee eebe Eege 5 13 PROVE A See eege eege ee 5 13 Wistallation e EE 5 14 Friction and Steel Plates Wear Damage Inspechon 5 14 Friction and Steel Plate Warp Inspechon AE 5 15 Spring Free Length Meester td ee tia pct 5 15 Clutch Housing Einger Joepecten iconos deis 5 15 Clutch Hub Spline Inspection a egegerk cette dedne deslads cia 5 15 gl NET 5 16 Removal KX85 A1 A5 B1 B5 KX100 D1 D ENEN 5 16 Installa
99. e the transmission shaft see Transmission Shaft Removal e Remove the crankshaft from the right crankcase half us ing a press Crankcase Disassembly Do not remove the bearings and the oil seals unless it is necessary Removal may damage them 6104060281 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 e Chip off the old gasket from the mating surfaces of the crankcase halves and clean off the crankcase with a high flash point solvent After cleaning apply engine oil to the transmission gears shift drum shift forks and bearings e Be sure to replace any oil seal removed with a new one Press in the new oil seal using a press and suitable tools so that the seal surface is flush with the surface of the crankcase e Apply high temperature grease to the oil seal lips e Press in the ball bearings using the bearing driver set until the bearing is bottomed Special Tools Bearing Driver Set 57001 1129 l the crankshaft bearings stay on the crankshaft when splitting the crankcase remove the bearings from the crankshaft and reinstall them in the crankcase as follows ORemove the bearings from the crankshaft with a bearing puller Special Tools Bearing Puller Adapter 57001 136 B Bearing Puller 57001 158 A ODiscard
100. e tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges NOTICE Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e Break the beads away from both sides of the rim with the bead breaker A Special Tool Bead Breaker Assembly 57001 1072 e Install the rim protectors around the valve stem Lubricate the tire irons and rim protectors with a soap and water solution or rubber lubricant Special Tool Rim Protector 57001 1063 B Bead Breaker Assembly 57001 1072 A e Step on the side of the tire opposite the valve stem and start prying the tire off the rim near the valve stem with tire irons Take care not to insert the tire irons so deeply that the tube gets damaged NOTE OFor easier removal always position the tire bead oppo site the valve stem in the rim well and pry the tire bead a little at a time e Remove the tube when one side of the tire is pried off e Pry the tire off the bead protector rear wheel e Pry the other side of the tire off the rim GJO50401S1 GJO50603S1 6J050104S1 8 10 WHEELS TIRES Tires Installation e Inspect the rim and tire and replace them if necessary e Install the tube e Apply a soap and water solution or rubber lubricant to the rim flange and tire beads e Position the tire on the rim
101. eaks 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 cm 2 18 psi e Remove the radiator cap and install a cooling system pressure tester A and adapter B on the radiator filler neck C NOTE OWet the adapter cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 125 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds If the pressure holds steady the cooling system is all right e Remove the pressure tester replenish the coolant and install the radiator cap lf the pressure drops and no external source is found check for internal leaks Check the cylinder head gasket for leaks Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flush the cool ing system If this accumulation is not removed it will clog up the water passages and considerably reduce the effi ciency of the cooling system e Drain the cooling system see Coolant Draining e Fill the cooling system with fresh water mixed with a flush ing compound Avoid the use of a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacturer of the cleaning produ
102. eated in the adjuster at the clutch lever or it could slip into the place later creating enough cable play to prevent clutch disengagement e Tighten the locknut e f it cannot be done loosen the locknut B at the middle of the clutch cable and turn the adjusting nut A so that clutch lever has 8 13 mm 0 3 0 5 in of play e After the adjustment is made tighten the locknut and start the engine and check that the clutch does not slip and that it release properly GR11005BS1 C 6R11007BS1 C 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 e Turn the clutch release lever toward the front until it be comes hard to turn this is the point where the clutch is just starting to release At this time check that the included angle A between the clutch release lever B and the line C at right angle to the right engine cover Clutch Release Lever Angle Standard approx 14 A x If it is not adjust the clutch lever angle by increasing or decreasing the number of shims A Removal e Slide the dust cover out of place e Loosen the locknut at the upper of the cable and turn the adjusting nut to give the cable plenty of play e Loosen the knurled locknut A at the clutch lever and sc
103. ection 3 12 COOLING SYSTEM Radiator Radiator Cap Inspection e 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 e Wet the top and bottom valve seals with water or coolant to prevent pressure leaks e Install the cap A on a cooling system pressure tester B e Watching the pressure gauge pump the pressure tester slowly to build up the pressure The gauge pointer must remain within the relief pressure range in the table be low at least 6 seconds Also when the pressure tester is pumped further the pointer must flick down the cap opens at a relief pressure in the table Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 14 18 psi x If the cap cannot hold the pressure or if the relief pressure is too high or too low replace the cap with a new one Filler Neck Inspection e Check the radiator filler neck for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly Water Hoses Connections Inspection e In accordance with the Periodic Maintenance Chart visu ally inspect the hoses for signs of deterioration Squeeze the hose A hose should not be hard and brittle nor should it be soft or swollen e Replace any damaged hose Water Hoses Breather Hose Installation
104. ection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Primary gear worn or chipped Abnormal Drive Train Noise Clutch noise Clutch housing friction plate clearance ex cessive Cutch housing gear primary gear backlash excessive Metal chip jammed in clutch housing gear teeth Transmission noise Crankcase bearing worn or damaged Transmission gear worn or chipped Metal chip jammed in gear teeth Transmission oil insufficient or too thin Kick ratchet gear not properly disengaging from kick gear Output shaft idle gear worn or chipped Drive chain noise Drive chain adjusted improperly Chain worn Rear and or engine sprocket s worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Master cylinder damaged Other noise Bracket nut bolt etc mounted or tightened not properly Exhaust Smoke Excessive white smoke Throttle cable maladjusted Crankshaft oil seal damaged Brownish smoke Air cleaner clogged Main jet too large of fallen out Choke plunger stuck open 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 unsati
105. ensor broken or maladjusted Ignition coil trouble Flywheel magneto damaged Ignition coil lead or C D I Unit lead not in good contact Fuel air mixture incorrect Idle adjusting screw maladjusted Pilot Slow jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Choke plunger stuck open Fuel level too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Crankshaft oil seal deteriorated or dam aged Compression Low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring land clearance excessive Cylinder head gasket damaged Cylinder head warped Cylinder base gasket damaged Reed valve damaged Cylinder nut loose Kips ports stuck open KIPS exhaust valve stuck open valve seizure or carbon accumulation KIPS exhaust valves assembled incorrectly Exhaust advancer spring damaged Exhaust valve operating rod seizure Rod for KIPS seized in cylinder Other C D I Unit trouble Transmission oil viscosity too high Brake dragging APPENDIX 15 3 Troubleshooting Guide Poor Running or No Power at High Speed Firing incorrect Spark plug dirty damaged or maladjusted Spark plug cap or high tension wiring dam aged Spark plug cap shorted or not in good con tact Spark plug incorrect C D I Unit trouble Crankshaft sensor broken or maladjusted Ign
106. ep or sub step it fol lows 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 spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing EE Model Identifica Ad General Specifications cerda iii diners iberica Periodic Maintenance Chart isc ii Rtl Viesgo le e y Locking Agent rirni iinoa aa eae tice enc eet the ieee as Saat OEE ae Sakata Special Tools and Sealants viii odas Cable Wire and Hose Routing EE 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 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 Battery Ground Disconnect the g
107. eplace e Engine sprocket inspect t e Coolant inspect t e R Water hoses connections inspect t e Reed valve inspect t e CHASSIS Brake adjustment inspect Brake pad wear inspect t o Brake fluid level inspect t e Brake fluid change Every 2 years Brake master cylinder cup and dust seal replace Every 2 years Brake caliper fluid seal and dust seal replace Every 2 years Brake hoses connections inspect t e Brake hose replace Every 4 years Spoke tightness and rim runout inspect t o Drive chain adjust e Drive chain lubricate e Drive chain wear inspect t Chain slipper and guide replace When damaged Front fork inspect clean o 1 14 GENERAL INFORMATION Periodic Maintenance Chart FREQUENCY OPERATION Front fork oil change Nuts bolts fasteners inspect t Fuel system clean Each race 2 5 hr 1st ti Every 3 Every 5 Every 10 races races 7 5 hr 12 5 hr As races required 25 hr me after 2 races then every 5 races Fuel hoses connections inspect t Fuel hose replace Steering play inspect t Every 4 years Steering stem bearing grease Rear sprocket inspect t General lubrication perform Wheel bearing inspect t Swingarm and Uni Trak linkage pivots grease Swingarm and Uni Trak linkage pivots inspect t Rear shock oil replace 1st t
108. er B Push Rod C Retainer D Piston Stop E Piston F Secondary Cup G Primary Cup H Return Spring I Circlip J Connector K O ring Special Tool Inside Circlip Pliers 57001 143 Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol NOTICE Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to the wash off completely and will eventually deteriorate the rubber used in the disc brake e Apply brake fluid to the removed parts and to the inner wall of the cylinder e Take care fluid to the removed parts and to the inner wall of the cylinder e Tighten the brake lever pivot bolt locknut to the specified torque Torque Brake Lever Pivot Bolt Locknut 5 9 N m 0 60 kgf m 52 in Ib 6L07010352 10 16 BRAKES Master Cylinder Inspection Visually e Disassemble the front and rear master cylinder e 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 Relief and Supply Port Plugged If they are damaged replace them BRAKES 10 17 Bra
109. er Pump Water Pump Shaft Removal e Remove Right Engine Cover see Engine Right Side chapter Primary Gear A see Engine Right Side chapter e Pull out the water pump shaft B Water Pump Seal Removal e Remove Impeller see Impeller Removal Right Engine Cover see Engine Right Side chapter e To remove the water pump seal remove the ball bearing firstly Olnsert a metal rod B into the right engine cover from the impeller side and remove the ball bearing tapping A around the inner race of the bearing C ORemove the water pump seal D tapping around the bot tom of the seal as same as bearing installation Water Pump Seal Installation If the water pump seal is removed replace the water pump bearing also e Apply plenty of high temperature grease to the water pump seal e Go first the soft side B of the water pump seal A and in sert the seal into the right engine cover from the opposite side C of the impeller e Press D the water pump seal until it bottoms to the right engine cover using the bearing driver set Special Tool Bearing Driver Set 57001 1129 e Install the water pump bearing E until it bottoms to the cover using the bearing driver set The marked side of the bearing faces outward Special Tool Bearing Driver Set 57001 1129 6D06050BS1 6D06051BS1 COOLING SYSTEM 3 11 Radiator Radiator Removal e Drain the coolant by re
110. er and upward softer e Tighten the locknut e Measure the nut position shown and adjust the spring as follows Spring Preload Setting Standard adjusting nut position B 73 mm 2 87 in Nut adjusting range 63 85 mm 2 48 3 35 in Standard Spring Set length 244 5 mm 9 63 in NOTE OAdjusting nut position and nut adjusting range applies to the optional springs e Tighten the locknut C securely e After adjustment move the spring up and down to make sure that the spring is seated e Install the parts removed e Torque Torque Rear Frame Pipe Bolts 34 N m 3 5 kgf m 25 ft Ib Removal e Remove the following Air Cleaner Housing see Preload Adjustment in this chapter e Raise the rear wheel off the ground see Wheels Tires chapter e Remove the following Tie Rod Bolt and Nut A Rear Shock Absorber Lower Bolt B Rear Shock Absorber Upper Bolt and Nut D e Support C rocker arm to slide out the bolts GM050615S1 6M050623S1 11 16 SUSPENSION Rear Shock Absorber When pulling out the mounting bolts lift the swingarm slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Remove the rear shock absorber Installation e Installation is the reverse of removal e Torque Torque Rear Shock Absorber Mounting Bolts 39 N m 4 0 kgf m 29 ft lb Tie Rod Nut 59 N m 6 0 kgf m 44 ft lb Rear Frame Pipe Bolts 34 N m 3 5
111. er nor the piston skirt get scratched e Install the dust seal around the piston Check that dust seal is properly fitted into the grooves in the piston and caliper e Replace the caliper holder shaft rubber boot and dust cover if they are damaged e Apply a thin coat of silicone grease to the caliper holder shafts and holder holes silicone grease is a special high temperature water resistant grease e Install the anti rattle spring A in the caliper as shown e Install the pads see Pad Installation Fluid Seal Damage Inspection The fluid seal around the piston maintains the proper pad disc clearance If this seal is not in good condition pad wear will increase and constant pad drag on the disc will raise brake and brake fluid temperature e Replace the fluid seals under any of the following condi tions a fluid leakage around the pad b brakes over heat c there is a large difference in left and right pad wear d the seal is stuck to the piston If the fluid seal is replaced replace the dust seal as well Also replace all seals every other time the pads are changed Dust Seal and Cover Damage Inspection e Check that the dust seals and covers are not cracked worn swollen or otherwise damaged If they show any damage replace them Piston Cylinder Damage Inspection e Visually inspect the piston and cylinder surfaces Replace the cylinder and piston if they are badly scored or rusty GLO5
112. ester 2 Engine stop switch 3 Crankshaft sensor peak voltage 4 Exciter coil peak voltage Use KAWASAKI Hand Tester Lacking of sampling Sampling few times Crankshaft sensor peak voltage Exciter coil peak voltage Replace the malfunctioned no good parts All good All good C D I Unit is defective No good Replace the malfunctioned parts or inspect in proper way GP10099B F 14 12 ELECTRICAL SYSTEM Ignition System A 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 e Install the crankshaft sensor so that the air gap clearance between the flywheel and the crankshaft sensor core has correct clearance see Flywheel Magneto Installation Crankshaft Sensor Air Gap Adjustment e Remove the magneto cover see Flywheel Magneto Re moval e Loosen the crankshaft sensor screws e Insert a 0 5 mm thickness gauge between the crankshaft sensor B core and the timing plate e While pressing the crankshaft sensor toward the magneto flywheel tighten the coil screws and remove the thickness gauge e Check the air gap A See Flywheel Magneto Installa tion Crankshaft Sensor Air Gap 0 4 0 6 mm 0 016 0 024 in If the air gap is not within the specified range readjust the gap Cranksha
113. ester B e 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 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Primary lead connection Adapter R lt Ground Adapter BK lt gt Orange A WARNING To avoid extremely high voltage shocks do not touch the spark plug or tester connections e Kicking the primary kick turn the engine several seconds with the transmission in neutral to measure the primary peak voltage e Repeat the measurements 5 or more times Ignition Coil Peak Voltage Standard 110 V or more lf the reading is less than the specified value check the following Ignition Coil Crankshaft Sensor CDI Unit Engine Stop Button Electric Current Inspection e Disconnect the engine stop button lead or connector e Start the engine e Ground the stop button lead or black yellow of the mag neto lead KX85A6F B6F KX100D6F while the en gine is running If the engine does not stop by this action replace the CDI unit NOTE O The Cause of trouble may be not able to clear enoughly by inspecting some items If the cause of trouble is not solved replace the CDI Unit with a new one 7 GP10062681 ELECTRICAL SYSTEM 14 17 Ignition System CDI Unit Troubleshooting 1 CDI unit or crankshaft sen
114. evel Inspection Engine Oil Change Crankcase Lucida Crankcase Splitting Crankcase Disassembly Crankcase Assembly Crankshaft Connecting Rod Crankshaft Removal Crankshaft Installation Crankshaft Disassembly Crankshaft Assembly Big End Seizure Inspection Table of Contents Crankshaft Bearing reel EE Connecting Rod Big End Radial Clearance Inspection Connecting Rod Big End Side Clearance Jnspecton Crankshaft Runout ASPE ice reia aaa Crankshaft Alignment Inspection EE Transmission ceceeeeeeeeeeeeeee ees Transmission Shaft Removal Transmission Shaft Installation eegener ai Seege EENEG Transmission Shaft Disassembly ccoo nica Jar errereen dios Shift Fork Bending Inspection das Shift Fork Gear Groove Wear Installation c cceeceeeeeeeeeeeeee ester ee eeeeneeeeeeeeeeeeeeeeeeeeeeea Shift Fork Guide Pin Shift Drum Groove Wear Inspection ocooooooccccnococcccnonanccccnnnnancnnnnns Gear Dog Gear Dog Hole Damage Inspection EE Ball Bearing Wear Inspection 7 2 7 5 7 5 7 5 7 7 7 7 7 7 7 10 7 10 7 10 7 10 7 10 7 10 7 10 7 11 7 11 7 11 7 12 7 13 7 13 7 13 7 13 7 13 7 14 7 15 7 15 7 15 7 15 7 2 ENGINE BOTTOM END TRANSMISSION Exploded View 61021878W4 C 1 Water Pump Gear G Apply grease 2 Primary Gear LG Apply liquid gasket Liquid Gasket 3 KX85 A1 A5 B
115. ft Sensor Inspection e Remove the following Magneto Lead Connector A e Set the hand tester to the x 100 Q range and connect it to the magneto lead connector crankshaft sensor lead connector Special Tool Hand Tester 57001 1394 If there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced Crankshaft Sensor Resistance W G W R Leads 396 594 Q x 100 Q e Using the highest resistance range of the hand tester measure the resistance between the crankshaft sensor leads and chassis ground Any hand tester reading less than infinity Leo indicates a short necessitating replacement of the stator a GP10062181 ELECTRICAL SYSTEM 14 13 Ignition System Crankshaft Sensor Peak Voltage Inspection e Disconnect the magneto lead connector C e Set the hand tester B to the x 25 V DC range and con nect it the Peak voltage adapter A as shown in the dia gram e Connect the black lead of the adapter to White Green lead and red lead to White Red lead of the magneto lead adapter e Kicking the primary kick turn the engine 4 5 seconds with the transmission gear in neutral to measure the crankshaft sensor peak voltage e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 4 0 V or more Special Tools Hand Tester 57001 1394 Peak Voltage Adap
116. g 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 Swingarm Bearing Removal e Remove Swingarm Dust Seals A Oil Seals B Sleeves C e Remove the needle bearings D using the bearing driver set Special Tool Bearing Driver Set 57001 1129 6M060606S1 C 6M06060751 6M060502S1 SUSPENSION 11 23 Swingarm SwingArm Bearing Installation e Replace the needle bearings dust seals and oil seals with new ones e Apply plenty of molibdenum disulfide grease to the dust seals oil seals and needle bearings NOTE Olnstall the needle bearings so that the manufacturer s marks face out Special Tool Bearing Driver Set 57001 1129 e Install the needle bearings A dust seals B and oil seals C position as shown 5 5 mm D OThe installation procedure is the same as the counter side Swingarm Pivot Inspection e Check the pivot of the swingarm and uni trak link tie rod and rocker arm for wear periodically or whenever exces sive play is suspected e Raise the rear wheel off the ground see Wheels Tires chapter e Move the swingarm A up and down to check for abnor mal friction and push and pull it to check for bearing play A small amount of play on the pivot is normal and no corrective action is needed However if excessive play is felt check the swin
117. garm and uni trak link bearings for wear and replace them if necessary A WARNING Installation of new bearing s in the swingarm and uni trak link can make the rear suspension action too stiff and adversly affect handling causing an accident resulting in serious injury or death To avoid injury always conduct a slow test ride un til suspension action is normal after installing new swingarm and or Uni Trak link bearings Swingarm Bearing Sleeve Inspection e The rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring in the swingarm for abrasion color change or other dam age x If there is any doubt as to the condition of any of the nee dle bearings of sleeves replace all the sleeves and nee dle bearings as a set 11 24 SUSPENSION Tie Rod Rocker Arm Tie Rod Removal e Raise the rear wheel off the ground see Wheel Tires chapter e Squeeze the brake lever slowly and hold it with a band e 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 Forcing or tapping ona E bolt could damage the bolt sleeve and bearing e Remove the tie rods B Tie Rod Installation e Apply plenty of molybdenum disulfide grease to the inside of the needle bearings and sleeves Rocker Arm Needle Bearings Tie Rod Needle Bearings e Install the
118. gf m 15 5 5 kgf m 40 1 5 kgfm 11 YH Fe 11 27 Nm T2 20 Nem T3 54 Nem T4 15 Nem KX100 D1 D2 2 KX85 A3 B3 KX100 D3 3 1 KX85 A1 A2 B1 B2 locking agent w L Apply a non permanen R Replacement parts SUSPENSION 11 3 Exploded View Q a gu i y y Ki Rn D ii VW 00 016 WO U GM020608W4 C 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 Nm 7 0 kgf m 51 ft lb Apply grease Apply a non permanent locking agent Apply Molybdenum disulfide grease The seal lips face outward aS Da DB Na N lt r O 11 4 SUSPENSION Specifications Item Service Limit Front Fork Air Pressure Atmospheric pressure re Compression Damping Adjustment Refer to 11 5 Oil Type KHL15 10 KAYABAO1 or equivalent Oil Capacity KX85A 315 4 mL 10 7 0 14 US oz KX85B KX100D 321 4 mL 10 9 0 14 US oz ae compressed spring Adjustable Range KX85A 100 2 mm 3 9 0 08 in 75 115 mm 3 0 4 5 in KX85B KX100D 90 2 mm 3 5 0 08 in 75 115 mm 3 0 4 5 in Fork Spring Free Length 430 mm 16 9 in 422 mm 16 6 in Rear Shock Absorber Compression Damper Setting 2nd position Adjustable Range upper 4 clicks Rebound Damper Setting 11th click from fully clockwise Adjustable Range lower position 20 clicks Spring Preload Setting Standa
119. he other end of the hose into a container e Change the brake fluid as follows ORepeat this operation until fresh brake fluid comes out into the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 Release the brake D OFill the reservoir with new brake fluid NOTE O The fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line e Remove the clear plastic hose e Tighten the bleed valves and install the rubber cap Torque Caliper Bleed Valve 7 8 N m 0 8 kgf m 69 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage If necessary bleed the air from the lines e Install the reservoir cap NOTE OFollow the procedure below to install the rear brake reservoir cap correctly OFirst tighten the rear brake reservoir cap B clockwise C by hand until slight resistance is felt indicating that the cap is seated on the reservoir body then tighten the cap an additional 1 6 turn D while holding the brake fluid reservoir body A Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all movement of the brake lever or pedal is tran
120. ifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it If cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Wheels Spoke Nipples Front Axle Nut Rear Axle Nut Final Drive Chain Adjuster Locknuts Brakes Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Brake Pedal Bolt Suspension Front Fork Clamp Bolts Rear Shock Absorber Mounting Bolts Swingarm Pivot Shaft Nut Uni Trak Tie rod amp Rocker Arm Pivot Shaft Nuts Steering Steering Stem Head Nut Handlebar Holder Bolts Engine Engine Mounting Nuts Cylinder Head Nuts Shift Pedal Bolt Muffler Mounting Bolts Kick Pedal Bolt Others Rear Frame Pipe Bolts Front Fender Mounting Bolt 15 8 APPENDIX Unit Conversion Table Prefixes for Units Units of Length Prefix Symbol Power KN x 06214 mile mega M x 1 000 000 in E AE kilo k x 1000 mm x 0 03937 in centi c x 0 01 milli m x 0 001 micro u x 0 000001 Units of Torque N m x 0 1020 kgf m Nam x 0 7376 ft lb Units of Mass N m x 8 851 in lb kg S 2 205 lb kgf m x 9 807 N m g z 0 03527 SE kgf m x 7 233 8 ft lb kgf m x 86 80 in Ib ra ee gal US Units of Pressure L x 0 2200 gal imp GE i a kati i ee Ee kPa lt 07501 Se Hg i GE e kgf cm x 98 07 kPa e i a P i kgf cm x 14 22 psi L x 1 816 pint imp mL x
121. ime after 2 races then every 5 races t Replace add adjust clean or torque if necessary R Replace 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 S Tighten the fasteners following the specified sequence St Stake the fasteners to prevent loosening Torque Fastener Nem kaf itib Remarks Fuel System Air Cleaner Housing Mounting Bolts 8 8 0 90 78 in lb Air Cleaner Holder Nuts 3 0 0 31 27 in lb Fuel Tap Plate Screws 0 8 0 08 7 in lb Reed Mounting Screws 1 0 0 10 9 in lb Carburetor Holder Mounting Bolts 8 8 0 90 78 in lb Carburetor Mounting Clamp Screw 1 5 0 15 13 in lb Rear Frame Pipe Bolts 34 3 5 25 Cooling System Water Hose Clamp Screws 1 5 0 15 13 in lb Radiator Stay Mounting Bolts 8 8 0 90 78 in lb Radiator Shroud Mounting Bolts 8 8 0 90 78 in lb Radiator Screen Mounting Bolts 8 8 0 90 78 in lb Radiator Mounting Bolts 8 8 0 90 78 in lb Coolant Drain Plug cylinder 8 8 0 90 78 in lb Coolant Drain Plug water pump 5 4 0 55 48 in lb Water Pump Impeller Bolt 7 0 0 70 61 in lb Water Pump Cover Bolts 8 8 0 90 78 in lb Engine Top End Muffler Mounting Bolts 78 in lb Exhaust Pipe Mounting Bolts 78 in lb Air Bleeder Bo
122. in rpm Uk MO Na aa KX85 B1 B5 KX85B6F KX85A6F NGK R6252K 105 Full open E 62 5 BBDC 62 5 ABDC 125 87 Low speed 93 5 High speed 87 Low speed 93 5 High speed Is rg 1 8 GENERAL INFORMATION General Specifications Reduction Ratio Overall Drive Ratio Transmission Oil 3 571 50 14 11 607 Top gear Items KX85 A1 A5 A6F AAF KX85 B1 B5 B6F BAF Duration 174 Low speed 187 High speed Lubrication System Petrol mix 32 1 Drive Train Primary Reduction System Type Gear Reduction Ratio 3 400 68 20 Clutch Type Wet multi disc Transmission Type 6 speed constant mesh return shift Gear Tatios 1st 2 538 33 13 2nd 1 875 30 16 3rd 1 500 27 18 D 4th 1 250 25 20 D 5th 1 090 24 22 6th 0 956 22 23 D Final Drive System Type Chain drive 3 923 51 13 12 758 Top gear Front Tire Size Type 70 100 17 40M Tube Engine Oil Grade API SG SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capacity KX85 A1 A3 0 65 L 0 69 US qt KX85 B1 B3 0 65 L 0 69 US at KX85 A4 0 70 L 0 74 US at KX85 B4 0 70 L 0 74 US at Frame Type Tubular semi double cradle E Steering Angle 45 to either side Caster rake angle 27 D Trail 89 mm 3 5 in 103 mm 4 1 in 70 100 19 EU 70 100 19 42M KX85 B5 70 100 19 42M lt lt
123. irclips retaining rings and cotter pins that were removed with new ones as re moval 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 Pos itive 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 There fore always replace these parts with new ones every time they are removed Although the
124. ition coil trouble Flywheel magneto damaged Ignition coil lead or C D I Unit lead not in good contact Fuel air mixture incorrect Main jet clogged or wrong size Jet needle or needle jet worn Jet needle clip in wrong position Fuel level too high or too low Air jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Choke plunger stuck open Crankshaft oil seal deteriorated or dam aged Fuel to carburetor insufficient Water or foreign matter in fuel Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Fuel tap clogged Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring and clearance excessive Cylinder head gasket damaged Cylinder head warped Cylinder base gasket damaged Reed valve damaged Cylinder nut loose Engine rpm will not rise properly Choke plunger stuck open Fuel level too high or too low Main jet clogged Throttle valve does not fully open Air cleaner clogged Muffler clogged Water or foreign matter in fuel Cylinder exhaust port clogged Brake dragging Clutch slipping Overheating Transmission oil level too high Transmission oil viscosity too high Crankshaft bearing worn or damaged KIPS ports stuck closed KIPS ports stuck closed KIPS exhaust valves stuck closed valve seizure or carbon accumulation KIPS exhaust valves assembled incorrectl
125. ke Disk Brake Disc Removal e Remove Front Wheel see Wheels Tires chapter Rear Wheel see Wheels Tires chapter e Remove the brake discs from the wheels Brake Disc Installation e Install the disc on the wheels so that the mark side of it faces out e Apply a non permanent locking agent to the thread of disc mounting bolts Torque Disc Bolts Front Rear 9 8 N m 1 0 kgf m 87 in Ib Wear Inspection Replace the disc if the sliding surfaces have worn past the service limit Front and Rear Disc Thickness Standard 2 85 3 15 mm 0 112 0 124 in Service Limit 2 5 mm 0 098 in Warp Inspection e Lift the wheel off the ground using the jack see Wheels Tires chapter e For front disc inspection turn the handlebar fully to one side e Set up a dial gauge against the disc A as shown and measure disc runout turning the wheel B slowly If runout exceeds the service limit replace the disc Disc Runout Standard TIR 0 12 mm 0 0047 in or less Service Limit TIR 0 3 mm 0 012 in GLO80604S1 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 e Check the brake fluid level in the reservoir NOTE OHold the reservoir horizontal when checking brake fluid level OThe front reservoir A must be kept above the lower level line B If the fluid
126. kgf m 25 ft Ib Spring Replacement In addition to the standard spring heavy and light springs are available If the standard spring is improper for your purpose select a proper one according to the rider s weight or course conditions e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Clean the threaded portion on the upper of the rear shock absorber e Hold the lower of the rear shock absorber with a vise e Using the stem nut wrenches A loosen the locknut and turn the adjusting nut all the way upward Special Tool Steering Stem Nut Wrench 57001 1100 e Slide down the rubber bumper A e Remove the spring retainer clip B from the shock ab sorber and lift off the spring C e Exchange the spring for an optional part e Install the spring and retainer clip e Adjust the spring preload e Install the rear shock absorber 6M050616S1 GM050617S1 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 e Remove the following Rear Shock see Rear Shock Absorber Removal Rear Shock Spring See Spring Replacement e Point the reservoir valve away from you Slowly release the nitrogen gas pressure from the gas reservoir A by pushing down the valve core B with a screwdriver
127. kshaft fit the crankcase halves to gether with a press on the tool A Press B Connecting Rod C Crankshaft Jig NOTE OConstantly check the alignment of the two crankcase halves the position of the transmission shafts and shift drum The front and rear of the crankcase must be pushed together evenly e Remove the crankshaft jig from the flywheel e Tighten the crankcase bolts to the specified torque start ing with the ones around the crankshaft and then the far ther ones Torque Crankcase Bolts 8 8 N m 0 90 kgf m 78 in Ib e Check to see that the crankshaft drive shaft and output shaft all turn freely in the neutral position l the crankshaft will not turn probably the crankshaft is not centered tap the appropriate end of the crankshaft with a mallet to reposition it e Spinning the output shaft shift the transmission through all the gears to make certain there is no binding and that all the gears shift properly e Assemble the engine e Install Clutch see Engine Right Side chapter Magneto Fly Wheel and Stator see Electrical System chapter Engine see Engine Removal Installation chapter 7 10 ENGINE BOTTOM END TRANSMISSION Crankshaft Connecting Rod Crankshaft Removal e See Crankcase Splitting Crankshaft Installation e See crankcase Assembly Crankshaft Disassembly Since assembly of the crankshaft demands exacting toler ances the disassembly of the crankshaft can only be do
128. l off the ground Special Tool Jack 57001 1238 e Pull out the axle to the right and drop the front wheel out of the forks 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 the disc does not touch the ground e Insert a wood wedge between the disc brake pads This prevents them from being moved out of their proper posi tion should the brake lever be squeezed accidentally Front Wheel Installation e Installation is the reverse of removal Note the following e Apply grease to the seals e Install the collars A on both sides of the hub e Tighten the front axle nut to the specified torque Torque Front Axle Nut 79 N m 8 1 kgf m 58 ft Ib e Insert a new cotter pin and bend it over the axle e Check the front brake A WARNING After servicing it takes several applications of the brake lever 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 lever is obtained by pumping the lever until the pads are against the disc 8 6 WHEELS TIRES Wheels Rims Rear Wheel Removal e Remove the following Axle Nut Cotter Pin A Rear Axle Nut B Caliper Mounting Bolts C e Using the jack A or a stand raise the rear wheel off the ground Special Tool Jack 57
129. lay Standard Adjustable to suit rider Service Limit 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 Front 2 85 3 15 mm 0 112 0 124 in 2 5 mm 0 098 in Rear 2 85 3 15 mm 0 112 0 124 in 2 5 mm 0 098 in Disc Runout Front TIR 0 12 mm 0 0047 in or less TIR 0 3 mm 0 012 in Rear TIR 0 12 mm 0 0047 in or less TIR 0 3 mm 0 012 in Brake Fluid Recommended Disc Brake Fluid Type DOT 4 Special Tool Inside Circlip Pliers 57001 143 BRAKES 10 5 Disc Brake Information A WARNING When working with the disc brake observe the pre cautions listed below 1 2 3 Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid Don t change the fluid in the rain or when a strong wind is blowing Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil
130. lt 78 in lb Spark Plug 20 Water Hose Clamp Screws 13 in lb Engine Mounting Nuts 22 Engine Bracket Nuts 22 Cylinder Head Nuts 18 S Cylinder Nuts 18 S Coolant Drain Plug cylinder 78 in lb Exhaust Valve Cover Mounting Bolts 46 in lb Exhaust valve lever mounting bolt 35 in lb L KIPS Cover Mounting Bolts 46 in lb Engine Right Side Water Pump Impeller Bolt 7 0 0 70 61 in lb Clutch Spring Bolts 9 3 0 95 82 in lb Clutch Hub Nut 88 9 0 65 1 16 GENERAL INFORMATION Torque and Locking Agent Fastener Torque Remarks kgf m ft Ib Primary Gear Nut 5 0 36 Lh Kick Lever Plug Screw St Kick Lever Boss Mounting Bolt 1 2 104 in lb Shift Shaft Return Spring Pin 2 2 16 L Right Engine Cover Bolts 0 90 78 in lb Clutch Cover Bolts 0 90 78 in lb Gear Set Lever Mounting Bolts 0 90 78 in lb Ratchet Guide Mounting Bolt 0 90 78 in lb Ratchet Guide Mounting Screw 0 53 46 in lb Oil Filler Cap 0 15 13 in lb Lever Shaft Retaining Bolt 0 55 48 in lb Lever Assembly Mounting Screw 0 65 56 in lb L KX85 A4 B4 Engine Removal Installation Engine Mounting Nuts 3 0 22 Engine Mounting Bracket Nuts 3 0 22 Swing Arm Pivot Shaft Nut 7 0 51 Engine Bottom End Transmission Engine Oil Drain Plug 1 5 11 Flywheel Nut 3 0 22 Shift Drum Cam Bolt 2 3 16 5 Return Spring Pin 2 2 16 L Crankcase Bolts 0 90 78 in lb Primary Gear Nut 5 0 36 Lh Output Shaft Bearing Retaining Screws 0 55 48 in lb Drive Shaft Bearing Retaining Bolts 0 90 78 i
131. moving the coolant drain plug Wa ter Pump e 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 e Install the water hoses see Water Hoses Breather Hose Installation e Fill the coolant see Coolant Filling Torque Radiator Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Coolant Drain Plug Water Pump 8 8 N m 0 90 kgf m 78 in Ib Radiator Inspection e Check the radiator core x lf there are obstructions to air flow remove them lf the corrugated fins are deformed carefully straighten them with the thin blade of a screwdriver A MULL Do not tear the radiator tubes while straightening the fins 6D070601Si xf the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one Cleaning e Remove the radiator see Radiator Removal NOTICE When cleaning the radiator with steam cleaner be careful of the following to avoid damage to the fins Keep the steam gun C over 0 5 m 20 in B away from the radiator Blow steam perpendicularly to the radiator face Never blow steam at angle against the fins but straight through fins in the direction of natural air flow 6D070603S1i A Cleaner Running Dir
132. mum Rebound Damping Force Adjustment e To adjust the rebound damping force turn the lower damping adjuster A to the desired position until you feel a Click OThe standard setting is the 11th click from the fully clock wise position If the damper setting feels too soft or too stiff adjust it NOTE OAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force Always make any damping adjustments in small steps and test their effects before using them in competition Preload Adjustment The spring adjusting nut on the rear shock absorber can be adjusted for different riding and loading conditions If the spring action feels too soft or too stiff adjust it in accordance with the following procedure e Remove the following parts Seat see Frame chapter Side Covers see Frame chapter Air Cleaner Duct Clamp loosen Air Cleaner Housing see Fuel System chapter 6M050614S1 Clockwise Harder ae Softer STD 23 11 tt Counterclockwise 20 a A tA tt AH HA Ht tA Seated position adjuster turned fully clockwise GM05061281 SUSPENSION 11 15 Rear Shock Absorber e 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 e Turning the adjusting nut A downward makes the spring action hard
133. n before removing them 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 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 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 High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent 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
134. n 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 this includes any appliance with a pilot light e Remove the carburetor see Carburetor Removal e Disassemble the throttle valve assembly as follows OHold the throttle valve return spring A compressed to gether with the spring seat B undo the end E of the throttle cable from the hook D of the throttle valve and free the spring and spring seat from the throttle valve C OSlide the jet needle C out of the throttle valve OPull out the snap ring A and remove the throttle cable from the carburetor cap B e Disassemble the carburetor body Starter Plunger Assembly D unscrew Idle Adjusting Screw and Spring E unscrew Air Screw and Spring F unscrew e Disassemble the carburetor body bottom end Float Bowl G Float H Pivot Pin I drive out Main Jet J Float Valve K Pilot Jet L Main Jet Holder M Needle Jet N Spring O Spring Seat P GC06061983 Assembly e Clean the disassembly parts NOTICE Do not overtighten the jets They could be damaged requiring replacement e Replace the float bowl O ring with a new one if it is dete riorated or damaged FUEL SYSTEM 2 13 Carburetor Cleaning A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the carburet
135. n lb Shift Drum Plate Bolts 1 0 87 in lb Wheels Tires Front Axle Nut 8 1 58 Rear Axle Nut 8 1 58 Spoke Nipple 0 15 0 31 13 27 in lb Caliper Mounting Bolts rear 2 5 18 Final Drive Rear Axle Nut 8 1 58 Rear Sprocket Nuts 3 3 24 Rear Sprocket Studs L Magneto Cover Bolts 1 0 87 in lb Brakes Bleed Valve 7 8 0 80 69 in lb Brake Hose Banjo Bolts 25 25 18 Front Brake Reservoir Cap Screws 1 5 0 15 13 in lb Rear Brake Reservoir Bolt 5 9 0 60 52 in lb Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb GENERAL INFORMATION 1 17 Torque and Locking Agent Torque Fastener Nam kgf m itib Remarks Brake Lever Pivot Bolt 5 9 0 60 52 in lb Brake Lever Adjust Locknut 4 9 0 50 43 in lb Front Master Cylinder Clamp Bolts 8 8 0 90 78 in lb S Caliper Mounting Bolts front rear 25 2 5 18 Disc Bolts front rear 9 8 1 0 87 in lb L Rear Master Cylinder Mounting Bolts 9 8 1 0 87 in lb Rear Master Cylinder Push Rod Locknut 18 1 8 13 Rear Caliper Pad Mounting Bolts 18 1 8 13 Brake Pedal Bolt 25 2 5 18 Suspension Front Fork Clamp Bolts Upper Lower 15 Front Fork Top Plug 20 Front Fork Push Rod Nut 11 Compression Valve Assembly 40 L Front Caliper Mounting Bolts 18 Rear Frame Pipe Bolts 25 Rear Shock Absorber Mounting Bolts 29 Swingarm Pivot Shaft Nut 51 Uni trak Rocker Arm Pivot Shaft Nuts 61 Rocker Arm Bracket Bolts 61 M Tie rod Nuts 44 Steering Steering Stem Head Nut 64 47 Steering Stem Nut Hand Tight
136. n some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine leads for signs of burning fraying etc Poor leads and bad connections will affect electrical system operation OMeasure coil and winding resistance when the part is cold at room temperature Safety Instructions A 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 14 6 ELECTRICAL SYSTEM Electrical Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc lf any wiring is poor replace the damaged wiring e Pull each connector apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the meter to the x 1Q range and lead the tester If the tester does not read 0 Q the lead is defective Re place the lead or the
137. ne by a shop having the necessary tools and equipment e f it should be necessary to disassemble the crankshaft use a press to remove the crankpin Crankshaft Assembly Since the assembly of the crankshaft demands exacting tolerances the disassembly and reassembly of the crank shaft can only be done by a shop having the necessary tools and equipment e Check that the connecting rod radial clearance is within specification see Connecting Rod Big End Radial Clear ance Inspection e Press the crank halves onto the crankpin until the con necting rod side clearance is within specification see Connecting Rod Big End Side Clearance Inspection e Adjust crankshaft runout until it is within specification see Crankshaft Runout Inspection Big End Seizure Inspection In case of serious seizure with damaged flywheels the crankshaft must be replaced xin case of less serious damage disassemble the crank shaft and replace the crankpin needle bearing side washers and connecting rod Crankshaft Bearing Inspection Since the ball bearings are made to extremely close tol erances the wear must be judged by feel rather than mea surement e Remove the following Piston see Engine Top End chapter Primary Gear see Engine Right Side chapter e Turn the crankshaft using the connecting rod If the bearings are noisy do not spin smoothly or have any rough spots replace them Torque Primary Gear Nut 49 N m 5 0 kgf m 36 ft I
138. new one Guide Bushes Oil Seal Dust Seal e Check the inner tube and replace it with a new one if damaged e Cover the groove of the inner tube A guide bush with vinyl B for protecting the lips of dust seal and oil seal e Install the dust seal Spring band side down C retaining ring D and oil seal marked side down E e Remove the vinyl 11 12 SUSPENSION Front Fork e Install the following onto the inner tube Washer A Outer Tube Guide Bush B Inner Tube Guide Bush C e 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 Special Tool Fork Oil Seal Driver 57001 1352 e Install the oil seal into the outer tube using the oil seal driver special tool e Install the following by hand Retaining Ring Dust Seal lt Cylinder Unit Installation gt e Replace the gasket A of the compression valve assem bly B with a new one e Hold the fork leg horizontally in a vise e Insert the cylinder unit in the inner tube e Check the O ring C on the compression valve assembly and replace it with a new one if damaged e Apply a non permanent locking agent to the threads D of the compression valve and screw the valve assembly into the bottom of the inner tube e Hold the cylinder unit with the fork cylinder holder and tighten the compression valve assembly to the specified t
139. ng C to the right side Air Cleaner Housing Installation e Installation is the reverse of the removal e Torque Torque Rear Frame Pipe Bolts D 34 N m 3 5 kgf m 25 ft Ib Air Cleaner Housing Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Air Cleaner Housing Assembly e Install the air cleaner duct A so that the lobe B of it faces to the left side and aligns with the left bolt of the housing Air Cleaner Duct A Lobe of the duct B Air Cleaner Housing C Projection show the hole which is assembled to the left bolt D Left Bolt E FUEL SYSTEM 2 17 Fuel Tank Fuel Tank Removal e Remove Seat see Frame chapter Air Scoop A e Turn the fuel tap to the OFF position e Pull the fuel hose off the fuel tap A 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 this includes any appliance with a pilot light e Remove the fuel tank band A and the fuel tank mounting bolt B e Remove the fuel tank e Drain the fuel tank Fuel Tank Installation e Check the rubber dampers A lf the dampers are damaged or deteriorated replace them e Be sure the fuel hose is clamped to the fuel tap to prevent leaks e Insert the fuel tank breather hose outlet end into the num ber plate hole see Cable Wire and Hose Rou
140. nkshaft by turning in the puller center bolt and tapping the head of the bolt lightly with a hammer while holding the puller body steady There is a Woodruff key in the crankshaft tapered portion NOTICE Never strike the grab bar or the flywheel itself Strik ing the bar can bond it If the flywheel is struck the magnets may lose their magnetism e Unscrew the stator mounting screws A and remove the stator plate with crankshaft sensor B and the wiring grommet C Installation e Install the stator plate with crankshaft sensor Torque Stator Mounting Screws 5 2 N m 0 53 kgf m 43 in Ib e Using a high flash point solvent clean off A any oil or dirt that may be on the crankshaft taper and the flywheel taper Dry them with a clean cloth ELECTRICAL SYSTEM 14 9 Flywheel Magneto e 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 e Fit the Woodruff key securely in the slot in the crankshaft before installing the flywheel e Hold the flywheel steady with the flywheel amp pully holder and tighten the flywheel nut to the specified torque Special Tool Flywheel amp Pully Holder 57001 1605 Torque Flywheel Nut 29 N m 3 0 kgf m 22 ft lb e Measure the crankshaft sensor air gap A Clearance be tween the flywheel and the crankshaft sensor B core
141. nt level B should be at the bottom of the filler neck NOTE OCheck the level when the engine is cold room or ambi ent temperature l the coolant level is low add the correct amount of coolant through the filler opening see Coolant Filling Breather Hose A Coolant Level B Filler Neck C Recommended coolant Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Coolant mixture ratio 1 1 Soft water 50 Coolant 50 Total amount 0 67 L 0 71 US gt Coolant Deterioration Inspection e Visually inspect the coolant If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system If the coolant gives off an abnormal smell check for a cooling system leak It may be caused by exhaust gas leaking into the cooling system 6D07008BSi 3 6 COOLING SYSTEM Coolant Coolant Draining A 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 Do not ingest coolant NOTE OPosition the motorcycle upright so that the coolant may be
142. on plates apply transmission oil to the surfaces of each plate to avoid clutch plate seizure e Torque the clutch hub nut Torque Clutch Hub Nut 88 N m 9 0 kgf m 65 ft lb NOTE OUse the clutch holder to prevent the clutch hub from rotating Special Tool Clutch Holder 57001 1243 e Apply molybdenum disulfide grease to the rubbing portion of the push rod e Torque the clutch spring bolts Torque Clutch Spring Bolts 9 3 N m 0 95 kgf m 82 in Ib NOTE OUse the flywheel holder to prevent the clutch front rotat ing Special Tool Flywheel Holder 57001 1313 Friction and Steel Plates Wear Damage Inspection e Visually inspect the friction and steel plates to see if they show any signs of seizure or uneven wear If any plates show signs of damage replace the friction plates and steel plates as a set e Measure the thickness A of the friction plates B with vernier calipers x If they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 8 2 9 mm 0 110 0 114 in Service Limit 2 7 mm 0 106 in GRO5010281 ENGINE RIGHT SIDE 5 15 Clutch Friction and Steel Plate Warp Inspection e 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 The gap is the amount of friction or steel plate warp If any
143. ons the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area 20 10 0 10 20 30 40C0 4 14 32 50 68 86 104 F ET AAA TE GSO9010BS1 ENGINE BOTTOM END TRANSMISSION 7 7 Crankcase Crankcase Splitting e 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 e Remove the engine see the Engine Removal Installation chapter e Set the engine on a clean surface while parts are being removed e Remove the following parts from the engine Cylinder Head see Engine Top End chapter Cylinder see Engine Top End chapter Piston Primary Gear see Engine Right Side chapter Kickstarter Assembly see Engine Right Side chapter Kickstarter Idle Gear A Gear Set Lever Shift Drum Plate B Output Shaft Sleeve C and O ring D OReplace the O ring on the output shaft with a new one e Remove the crankcase bolts A e Install the crankcase splitting tool and adapter into the left side of the crankcase Be certain to screw the tool in all the way Special Tools Crankcase Splitting Tool Assembly 57001 1098 A Bearing Puller Adapter 57001 136 B e Tighten the bolt on the crankcase splitting tool to split the crankcase halves e Once the crankcase is split remove the crankcase split ting tool and lift off the left crankcase e Remov
144. or 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 Do not use gasoline or a low flash point solvent to clean the carburetor e Disassemble the carburetor see Disassembly NOTICE Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbu retor with a cleaning solution This will prevent damage or deterioration of the parts Do not use a strong carburetor cleaning solution which could attack the plastic parts instead use a mild high flash point cleaning solution safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Immerse all the metal parts into a carburetor cleaning so lution e Rinse the parts in water e After the parts are cleaned dry them with compressed air e Blow through the air and fuel passages with compressed air e Assemble the carburetor and install it on the motorcycle Inspection A 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 this includes any appliance with a pilot light e Remove the carburetor see Carburetor Removal e Before disassembling the carburetor check the fuel level see
145. or over flow tube through the clamp installed on the magneto cover 8 Carburetor Air Vent Tube 9 Magneto Lead 10 Do not cross the carburetor air vent tube and magneto lead 11 Run the fuel hose toward the outside of the carburetor air vent tube 12 Ignition Coil Primary Lead O 13 Ignition Coil Ground Lead BK 14 CDI Unit Ground Lead BK O 15 KX85A6F B6F KX100D6F 1 26 GENERAL INFORMATION Cable Wire and Hose Routing Front Brake System V i i Es Rear Brake System GB090646W4 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 Rear Brake Hose 6 Brake Hose Cover 14 Rear Brake Caliper 7 Front Brake Disc 15 Rear Brake Disc 8 Rear Brake Fluid Reservoir GENERAL INFORMATION 1 27 Cable Wire and Hose Routing AO d D 5 H D d G5 ty f E SA h Sse 6B09116CW4 C 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 Band Radiator Hose and KIPS Chamber Vent Tube 5 KIPS Chamber Vent Tube 6 Breather Hose 7 Water Hose Upper FUEL SYSTEM 2 1 Fuel System Table of Contents Exploded VieWeizccesessciocvizdstessscgvaacs cds Specifications sonia Throttle Grip
146. orque Special Tool Fork Cylinder Holder 57001 1413 Torque Compression Valve Assembly 54 N m 5 5 kgf m 40 ft lb lt Top Plug Installation gt e Hold the fork leg vertically in a vice e Install the spring guide A so that the longer taper B is down GM040616S1 6M040420S1 GM040617S1 GM040618S1 SUSPENSION 11 13 Front Fork e Screw the push rod nut until it touched the spring guide e Pour in the type and amount of fork oil specified and adjust the oil level see Fork Oil Level Adjustment e Screw the fork push rod puller A onto the end of the push rod Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 e Install the fork spring into the inner tube e Press the fork spring down while pulling up on the fork push rod puller special tool e Insert the fork spring holder B in on top of the fork spring and under the push rod nut C Special Tool Fork Spring Holder 57001 1286 e Remove the fork push rod puller special tool e Set the spring seat A on the fork spring so that the con vex side B is up e Check the O ring on the top plug and replace it with a new one if damaged e Tighten the top plug finger tight e Holding the top plug C with a wrench tighten the push rod nut D against the top plug to the specified torque Torque Front Fork Push Rod Nut 15 N m 1 5 kgf m 11 in Ib e Pull out the fork spring
147. ose as shown in the Cable Wire and Hose Routing section of the General Information chapter e Torque Torque Handlebar Holder Bolts 25 N m 2 5 kgf m 18 ft Ib Front Fork Clamp Bolts 20 N m 2 0 kgf m 15 ft Ib Steering Stem Head Nut 64 N m 6 5 kgf m 47 ft Ib e Check and adjust the following items after installation Steering see Adjustment Throttle Cable see Fuel System chapter Clutch Cable see Clutch chapter Front Brake A WARNING After servicing it takes several applications of the brake lever 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 lever is obtained by pumping the lever until the pads are against the disc Bearing Seal Deterioration Damage Inspection e Inspect the grease seal of the upper and lower bearings for any signs of deterioration or damage x Replace the bearing if necessary STEERING 12 7 Steering Stem Steering Stem Warp Inspection e 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 GNO50303S1 12 8 STEERING Steering Stem Bearing Removal e Remove the steering stem see Steering Stem Removal e To remove the outer races pres
148. osen some spokes and tighten parts of the rim If the rim is badly bent however it must be replaced Rim Runout with tire Installed Standard Axial TIR 1 0 mm 0 04 in or less Radial TIR 1 0 mm 0 04 in or less Service Limit Axial TIR 2 0 08 in mm Radial TIR 2 0 08 in mm 6J04131BS1 C 8 8 WHEELS TIRES Wheels Rims Axle Inspection e 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 x If the runout exceeds the service limit replace the axle Axle Runout 100 mm 3 94 in Standard 0 10 mm 0 004 in or less Service Limit 0 2 mm 0 008 in 604010281 WHEELS TIRES 8 9 Tires Removal e Remove the following Wheel see Wheel Removal Disc 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 e To maintain wheel balance mark A the valve stem posi tion on the tire with chalk so that the tire can be reinstalled in the same position e Take out the valve core B to let out the air e Fully loosen the valve stem nut C on the rear tire OWhen handling the rim be careful not to damage the alu minum rim flanges e Lubricate th
149. oward the rear e Stick the new right engine cover gasket in position with a thin layer of grease e Torque Torque Right Engine Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib KX85 A4 B4 KX100 D4 e Apply a non permanent locking agent to the thread of lever assy mounting screw e 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 Torque Lever Assy Mounting Screw 6 4 N m 0 65 kgf m 56 in Ib e Push A the shaft lever B and install the link lever C to the valve shaft D GRO40601S1 GRO406038S1 ENGINE RIGHT SIDE 5 11 Right Engine Cover e Run the clutch cable and the water hoses according to the Cable Wire and Hose Routing section in the General Information chapter e Adjust the clutch cable see Clutch Cable Free Play Ad justment e Check the clutch release lever angle see Clutch Release Lever Angle Inspection and Adjustment e Fill the crankcase with engine oil see Engine Bottom End Transmission chapter e Fill the engine with coolant see Cooling System chapter Right Engine Cover Disassembly e Remove the right engine cover e Unscrew the lever shaft retaining bolt A e Turn the lever shaft B and pull out it e Take off the advancer assembly A GRO40602S1 Advancer Disassembly KX85 A3 B3 KX1
150. pection and Adjustment after Installation ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeseeeeeeeeeeees 10 14 Front Master Cylinder Disassembly Au 10 14 Rear Master Cylinder Disassembhy non n cnn cnn nnncnnnnnnnccns 10 15 ASS it A dicos 10 15 Inspection MIS secs rosal ce UI Res lia 10 16 Brake DISK ioeina area Eed 10 17 Brake DIS Removal EEN 10 17 Brake DISC Installation niro ed ieai ias 10 17 A O aaa aA aa aa 10 17 Warp Inspection BEE 10 17 Brake EE 10 18 Fluid Level INSpeEctON iia aa EE Ee 10 18 Brake Ee EE 10 18 Bleeding the Brake LIS uni 10 19 Brake le 10 21 nn e Me tall AON EEN 10 21 Inspection EE 10 21 10 2 BRAKES Exploded View GLO2347BW4 C L R KX85A9F KX85B9F KX100D9F 5 9 Nm 0 60 kgf m 52 in lb 1 5 Nm 0 15 kgf m 13 mb 7 8 Nm 0 80 kgf m 69 in lb 8 8 Nm 0 90 kgf m 78 mb 9 8 N m 1 0 kgf m 87 mb 25 Nem 2 5 kgf m 18 ft lb 4 9 Nm 0 50 kgf m 43 mb Apply a non permanent locking agent Replacement parts i Apply silicone grease BRAKES 10 3 Exploded View GL02236BW4 C 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 R Replacement parts Si Apply silicone grease 10 4 BRAKES Specifications Item Brake Adjustment Brake Lever Free P
151. plate is warped over the service limit replace it with a new one Friction and Steel Plates Warp Standard 0 15 mm 0 006 in or less Service Limit 0 3 mm 0 012 in Spring Free Length Measurement e Since the spring A becomes shorter as it weakens check its free length to determine its condition If any of the springs is shorter than the service limit it must be replaced Clutch Spring Free Length Standard 35 0 mm 1 378 in Service Limit 34 0 mm 1 339 in 6RO50104S1 Clutch Housing Finger Inspection e Visually inspect the fingers A of the clutch housing where the tangs B of the friction plate hit them If they are worn or if there are groove cut where the tangs hit replace the housing Also replace the friction plates if their tangs are damaged Clutch Hub Spline Inspection e Visually inspect where the teeth on the steel plates wear against splines A of the clutch hub lf there are notches worn into the splines replace the clutch hub Also replace the clutch plates if their tooth are damaged GRO50606S1 5 16 ENGINE RIGHT SIDE Primary Gear Removal KX85 A1 A5 B1 B5 KX100 D1 D5 e Remove the right engine cover see Right Engine Cover Removal e Remove the circlip A then pull out the primary gear B Special Tool Outside Circlip Pliers 57001 144 Installation KX85 A1 A5 B1 B5 KX100 D1 D5 e Install the primary gear with the chamfer sid
152. push rod e Remove the fork spring holder special tool e Lift the fork spring B and its top spring seat C out of the inner tube 6M040611S1 e Hold the fork tube A upside down over a clean container B and pump it to drain the oil NOTE OTo discharge the fork oil pump the push rod C up and down more than ten time 6M040117S1 lt Filling with Oil gt e Hold the fork leg vertically in a vise and fully compressed NOTE O The spring should not be installed e Fill the front fork to the top with specified oil Recommended Fork Oil KHL15 10 KAYABA 01 or equivalent Fork Oil Capacity completely dry KX85A 315 4 mL 10 7 0 14 US oz KX85B KX100D 321 4 mL 10 9 0 14 US oz NOTE OWhile doing this take care to keep the oil level topped off that it stays above the two large holes A near the top of the inner tube B Y 7 AY SMA SSS IWS Keser Mie KSSSSSSSSSSSSSSSSSSSS Y GM040109S1 SUSPENSION 11 7 Front Fork e Screw the fork piston rod puller A onto the end of the rod Special Tool Fork Piston Rod Puller M10 x 1 0 57001 1298 e Purge the air from the fork cylinder by gently moving the rod puller A up and down five times 6M040111S1i e Purge the air from between the inner and outer A tubes by pumping the outer tube up and down 6M040110S1 NOTICE Never extend A
153. que Magneto Cover Bolts 9 8 N m 1 0 kgf m 87 in Ib Rear Sprocket Removal e Loosen the rear sprocket nuts e Remove the rear wheel see Wheels Tires chapter 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 e Remove the rear sprocket nuts and rear sprocket Rear Sprocket Installation e Install the rear sprocket A so that the marked B side faces out e Tighten the rear sprocket nuts to the specified torque Torque Rear Sprocket Nuts 32 N m 3 3 kgf m 24 ft lb nc GKO5004BS1 Sprocket Wear e Visually inspect the engine and rear sprocket teeth lf the teeth are worn as illustrated replace the sprocket and inspect the drive chain and engine sprocket see Drive Chain Wear Inspection Worn Tooth Engine Sprocket A Worn Tooth Rear Sprocket B Direction of rotation C GKO5017BS1 If a sprocket requires replacement the drive chain is probably worn also Upon replacing the rear sprocket inspect the chain and engine sprocket NOTE OSprocket wear is exaggerated for illustration 9 8 FINAL DRIVE Sprockets Rear Sprocket Warp e Using the jack or a stand raise the rear wheel off the ground see Wheels Tires chapter Special Tool Jack 57001 1238 e Set a dial gauge A against the rear sprocket B near the teeth as shown Turn C the
154. que Torque Brake Pedal Bolt 25 N m 2 5 kgf m 18 ft Ib e Check the brake pedal position e Install the joint pin and a new cotter pin see Pedal Posi tion Adjustment 10 8 BRAKES Calipers Caliper Removal e Loosen the banjo bolt A so as not to spill brake fluid e Remove the caliper mounting bolts B e Remove the caliper C e Remove the banjo bolt and take off the brake hose from the caliper see Brake Hose Removal Installation e f the caliper is to be disassembled after removal and if compressed air is not available remove the piston using the following steps before disconnecting the brake hose from the caliper ORemove the pads OPump the brake lever or pedal to remove the piston Immediately wash away any brake fluid that spills Caliper Installation e Tighten the caliper mounting bolts to the specified torque Torque Caliper Mounting Bolts Front Rear 25 N m 2 5 kgf m 18 ft lb e Connect the brake hose to the caliper putting a new flat washer on each side of the brake hose fitting e Tighten the banjo bolt to the specified torque Torque Brake Hose Banjo Bolts 25 N m 2 5 kgf m 18 ft Ib e Check the fluid level in the reservoir and bleed the brake line see Bleeding the Brake e Check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever or pedal before the brake pads contact the disc
155. r bleeder bolt hole until it overflows that is until all the remaining air is forced out e Install the air bleeder bolt securely e Fully extend the push rod assembly e Inject nitrogen gas to a pressure of 50 kPa 0 5 kgf cm 7 psi through the valve on the gas reservoir e Check the rear shock body and gas reservoir for oil and gas leaks If there are no leaks inject the nitrogen gas up to 980 kPa 10 kgf cm 142 psi A WARNING High pressure gas is dangerous and can explode causing serious injury To avoid injury have a qual ified mechanic pressurize the shock reservoir with nitrogen gas only Do not use air or other gases since they may cause premature wear rust fire haz ard or substandard performance NOTE OCheck and adjust the gas pressure when the gas reser voir is cold room temperature e Install the spring and retainer clip OBoth damping adjusters must face to the same side Compression Damping Adjuster A Rebound Damping Adjuster B e Adjust the following Spring Preload Compression Damping Adjuster e Install the rear shock absorber see Rear Shock Absorber Removal Disassembly e Drain the oil and disassemble the rear shock body see Oil Draining e Using a suitable tool collar or nut A and press push the reservoir cap B in 10 mm 0 394 in e Remove the circlip C from the gas reservoir 6M050620S1 11 20 SUSPENSION Rear Shock
156. rake lever or 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 lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc Front Master Cylinder Disassembly e Remove the following parts Front Master Cylinder see Front Master Cylinder Re moval Brake Lever Pivot Bolt and Locknut Brake Lever Dust Cover Retainer use the inside circlip pliers 57001 143 Piston complete with Secondary Cup Primary Cup and GLO7096BS1 Spring NOTICE Do not remove the secondary cup from the piston since removal will damage them A Dust Cover B Retainer C Washer D Piston E Secondary Cup F Primary Cup G Return Spring Special Tool Inside Circlip Pliers 57001 143 BRAKES 10 15 Master Cylinder Rear Master Cylinder Disassembly NOTE ODo not remove the push rod clevis for master cylinder disassembly since removal requires brake pedal posi tion adjustment e 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 Push Rod with Clevis installed Piston complete with Secondary Cup Primary Cup and Spring NOTICE Do not remove the secondary cup from the piston since removal will damage them A Dust Cov
157. ration and replenished as necessary Hold the brake applied A Quickly open and close the valve B Release the brake C NOTE Olf the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over again from the beginning since air will have en tered the line Olf the brake lever action still feels soft or spongy tap the brake hose from bottom to top and air will rise up to the top part of the hose Slowly pump the brake lever in the same manner as above e Remove the clear plastic hose e Tighten the bleed valve to the specified torque and install the rubber cap Torque Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage A WARNING After servicing it takes several applications of the brake lever 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 lever is obtained by pumping the lever until the pads are against the disc GLO9060582 C BRAKES 10 21 Brake Hose Removal installation e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss
158. rd Adjusting Nut Position 73 mm 2 87 in Nut Adjusting Range 63 85 mm 2 48 3 35 in Standard Spring Set Length 244 5 mm 9 63 in Rear Shock Absorber Oil Type KHV10 K2C KAYABA SAE 5W or Bel Ray SE2 40 Capacity 161 ml 5 44 US oz Gas Pressure 980 kPa 10 kgf cm 142 psi Spring Free Length 256 mm 10 1 in 250 mm 9 8 in Special Tools Steering Stem Nut Wrench 57001 1100 Bearing Driver Set 57001 1129 Jack 57001 1238 Fork Spring Holder 57001 1286 Fork Oil Level Gauge 57001 1290 Fork Piston rod Puller M10 x 1 0 57001 1298 Fork Cylinder Holder 57001 1413 Fork Oil Seal Driver 57001 1352 Fork Outer Tube Weight 57001 1218 SUSPENSION 11 5 Front Fork Air Pressure Adjustment OThe 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 e Lift the front wheel off the ground using the jack special tool and a stand see Wheels Tires chapter Special Tool Jack 57001 1238 e Remove the screws A on the fork top plug NOTE ODo not use the side stand when adjusting the air pres sure OAajust the air pressure when the front forks are cold e Check the O ring of the screw Replace the O ring with a new one if damage e Install the screw e Remove the jack and stand Compression Damping Adjustment e Place the jack under the fram
159. rew in the adjuster B e Line up the slots C in the clutch lever knurled locknut and adjuster and then free the cable from the clutch lever e Free the clutch inner cable tip from the clutch release lever NOTICE Do not remove the clutch release shaft unless it is absolutely necessary If removed release shaft oil seal must be replaced with a new one e Pull the clutch cable out of the frame GFO4002BS1 ENGINE RIGHT SIDE 5 7 Clutch Cable Installation e Run the clutch cable according to the Cable Wire and Hose Routing section in the General Information chapter e Adjust the clutch cable see Free Play Adjustment Lubrication and Inspection e Lubricate the clutch cable using the pressure cable luber in accordance with the Periodic Maintenance Chart e With the cable disconnected at both ends the cable should move freely within the cable housing see Gen eral Lubrication in the Appendix chapter 6004011481 5 8 ENGINE RIGHT SIDE Clutch Cover Clutch Cover Removal e Drain the engine oil see Transmission Oil Change in the Engine Bottom End Transmission chapter e Remove the brake pedal see Brake Pedal Removal in the Brake chapter e Free the clutch inner cable at clutch lever side see Clutch Cable Removal e Unbolt the clutch cover bolts A and take off the clutch cover B Clutch Cover Installation Notes e There are two knock pins on th
160. round 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 Installation Assembly Generally installation or assembly is the reverse of removal or disassembly However if instal lation 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 assem bled in the same way It is preferable to mark and record the locations and routing whenever possible 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 tur
161. running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily Then stop the engine e Place an oil pan beneath the engine e Remove the engine oil drain plug A on the bottom of the engine and let the engine oil drain completely NOTE OHold the motorcycle upright so that the oil may drain completely 6117060181 7 6 ENGINE BOTTOM END TRANSMISSION Transmission Oil e Check the gasket at the engine drain plug for damage x Replace the gasket with a new one if it is damaged After the oil has completely drained out install the engine drain plug with the gasket and tighten it to the specified torque Torque Engine Oil Drain Plug 15 N m 1 5 kgf m 11 ft lb e Fill the engine with a good quality motor oil specified in the table e 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 or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capacity 0 65 L 0 69 US qt 0 70 L 0 74 US qt NOTE ODo not add any chemical additive to the oil Oils fulfilling the above requirements are fully formulated and provide adequate lubrication for both the engine and the clutch OAlthough 10W 40 engine oil is the recommended oil for most conditi
162. s no play and the steering stem turns smoothly without the rattle lf not the steering stem bearing may be damaged OAgain back out the stem nut a fraction of turn until it turns lightly OTurn the stem nut lightly clockwise until it just becomes hard to turn Do not overtighten or the steering will be too tight Lubrication e Perform the following ORemove the steering stem OUsing a high flash point solvent wash the upper and lower tapered roller bearings in the cages OWipe the upper and lower outer races which are press fitted into the frame head pipe clean of grease and dirt OVisually check the outer races and the rollers Replace the bearing assemblies if they show wear or damage OPack the upper and lower tapered roller bearings in the cages with grease and apply light coat of grease to the upper and lower outer races Olnstall the steering stem and adjust the steering see Steering Adjustment Wear Damage Inspection e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer races and the rollers Replace the bearing assemblies if they show damage NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearings includ ing outer races should be replaced with new ones FRAME 13
163. s oil Removal e Remove the clip from the master link A using pliers and free the drive chain from the rear sprocket e Remove the drive chain from the chassis Installation e Fit the drive chain back onto the sprockets with the ends at the rear sprocket e Install the master link from the frame side e Install the clip A so that the closed end of the U B pointed in the direction of chain rotation C e Adjust the drive chain slack see Drive Chain Slack Ad justment e Check the rear brake effectiveness A 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 6K04030351 6K04003BS1 GKO4076BS1 FINAL DRIVE 9 7 Sprockets Engine Sprocket Removal e Remove the following parts Magneto Cover Drive Chain A free of engine sprocket e Remove the engine sprocket circlip B and pull off the engine sprocket C Special Tool Outside Circlip Pliers 57001 144 GKO50601S1 Engine Sprocket Installation e Replace the engine sprocket circlip with a new one e Install the circlip so that the tooth is aligned with a spline groove see above Tor
164. sed into the head pipe install the outer race remover as shown below Special Tool Head Pipe Outer Race Remover ID gt 37 mm 57001 1107 A e Remove the lower tapered roller bearing A which is pressed onto the steering stem with a suitable commer cially available tool Installation e Apply grease to the outer races and then drive them into the head pipe using the drivers and the press shaft Special Tool Head Pipe Outer Race Press Shaft 57001 1075 A Head Pipe Outer Race Driver 46 5 57001 1106 B OApply grease to the lower tapered roller bearing A and drive it onto the steering stem using the bearing driver and adapter Special Tool Bearing Driver 32 57001 382 B Steering Stem Bearing Driver Adapter 57001 1092 C e The following steps should be performed after steering bearing installation This procedure settles the bearings in place OUsing the stem nut wrench A tighten the stem nut to 39 N m 4 0 kgf m 29 ft lb of torque To tighten the steering stem nut to the specified torque hook the wrench on the stem nut and pull the wrench at the hole by 22 2 kg 49 lb force in the direction shown Special Tool Steering Stem Nut Wrench 57001 1100 Torque Steering Stem Nut 4 9 N m 0 49 kgf m 43 in Ib GNO70106S1 GNO40101S1 GNO70108S1 6N050415S1 GNO506048S1 STEERING 12 9 Steering Stem Bearing OCheck that there i
165. sfactory Handlebar hard to turn Too hard Control Cable routing incorrect Wiring routing incorrect Steering stem locknut too tight Bearing ball damaged Bearing race dented or worn Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm sleeve or needle bearing dam aged Rim warped or not balanced Front rear axle runout excessive Wheel bearing worn Handlebar holder loose Steering stem head nut loose Handlebar pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Front fork oil excessive Front fork oil viscosity too high Front fork leg bent Tire air pressure too high Rear shock absorber maladjusted Too soft Front fork oil insufficient and or leaking Front fork oil viscosity too low Front fork rear shock absorber spring weak Rear shock absorber gas leaking Rear shock absorber maladjusted Brake Doesn t Hold Disc brake Air in the brake line Pad or disc worn Brake fluid leak Disc warped Contaminated pads Brake fluid deteriorated Primary or secondary cup damaged Master cylinder scratched inside Brake maladjustment lever or pedal play excessive 15 6 APPENDIX General Lubrication Lubrication Periodic Maintenance e Before lubricating each part clean off any rusty spots with rust remover and wip
166. single cylinder piston reed valve Liquid cooled 52 5 x 45 8 mm 2 1 x 1 8 in 99 cm 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 Items KX100 D1 D5 D6F DOF 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 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 a Aa en Sa wa we ae o Chain drive 3 923 51 13 12 758 Top gear Engine Oil Grade API SE SF or SG API SH SJ SL or SM with JASO MA MA1 or MA2 Viscosity SAE 10W 40 Capacity KX100 D1 D3 0 65 L 0 69 US qt KX100 D4 0 70 L 0 74 US qt Frame Type Tubular single cradle Steering Angle Caster rake angle Trail Front Tire Size Type Rear Tire Size Type Rim Size Front Rear Front Suspension Type Wheel Travel 45 to either side
167. smitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power Bleed the air from the brake whenever brake lever or pedal action feels soft or spongy after the brake fluid is changed or whenever a brake line fitting has been loos ened for any reason GLOSO609S1 6L09060452 C Ni cy re OT J ge 10 20 BRAKES Brake Fluid NOTE O The proceaure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Bleed the air whenever brake parts are replaced or re assembled e Remove the reservoir cap and fill the reservoir with fresh brake fluid e Slowly pump the brake lever or pedal several times until no air bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir This bleeds the air from the master cylinder and the brake line NOTE O Tap the brake hose lightly going from the caliper to the reservoir side and bleed the air off at the reservoir e Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a con tainer e Bleed the brake line and the caliper as follows e The fluid level must be checked several times during the bleeding ope
168. sor is damaged 2 Even if the preceding checks show good it may be defective in some manner not readily detectable with igniter checker peak voltage adapter or hand tester Beginning Inspect CDI unit and crankshaft sensor Do above inspections prove that CDI unit and crankshaft sensor are good T Replace damaged part Does engine still operate poorly Replace CDI unit Replace part which was not replaced above Does engine still operate poorly Does engine still operate poorly Replace crankshaft sensor Does engine still operate poorly Trouble may be caused by other ignition system parts or engine itself GP10278B F APPENDIX 15 1 Appendix Table of Contents reien lte BETEN 15 2 General LupricatloN EE 15 6 Lubrication Periodic Maintenance scooter cias 15 6 Bolt Nut and Fastener Tightness oooccococcconcconooonooccnnncnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnneniness 15 7 TIGHINESS IMSPSCHOM EE 15 7 Unit Conversion Table 15 8 15 2 APPENDIX Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Engine won t turn over Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure
169. stall the parts removed see Oil Level Adjustment e Install the front fork leg see Front Fork Installation e Change the fork oil in the other fork leg in the same man ner Fork Outer Tube B Top of Fork Outer Tube C 6M04012752 Front Fork Removal e Remove the left and right front fork protectors A e Remove the brake hose clamp B e Remove the brake hose cover C e Remove the front wheel see Wheels Rims chapter e Remove the brake hose guide D e Remove the front caliper from the front fork leg and put it on the suitable stand so that it does not free in the air e Loosen the upper and lower front fork clamp bolts A e Turning the both fork legs to the left and right and pull them downward Front Fork Installation e When the front fork shall be disassembled the fork oil level should be inspected e Install the brake cable and hose see General Information chapter e Install the front wheel see Wheels Rims chapter Torque Front Fork Clamp Bolts upper lower 20 N m 2 0 kgf m 15 ft lb Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb 11 10 SUSPENSION Front Fork NOTE O Tighten the two clamp bolts alternately two times to en sure even tightening torque e Check the front brake for good braking power no brake drag and no fluid leakage after installing the front fork Disassembly each fork leg e Loosen the fork top plug temporarily e Remove the front fork
170. swingarm pivot shaft also serves as the engine mounting bolt removing it may cause the motorcycle to fall over and cause injury When removing the swingarm pivot shaft be sure the frame is well supported so the motorcycle will not fall when the pivot is removed e Pull out the swingarm pivot shaft C halfway so that the engine is free GHO40605S1 6 4 ENGINE REMOVAL INSTALLATION Engine Removal Installation e Move the engine forward and remove it from the vehicle right or left side Installation e Engine installation is the reverse of removal e Torque Torque Swingarm Pivot Shaft Nut 69 N m 7 0 kgf m 51 ft Ib Engine Mounting Bracket Nuts 29 N m 3 0 kgf m 22 ft lb Engine Mounting Nuts 29 N m 3 0 kgf m 22 ft lb e To install parts removed refer to the appropriate chapters e Run the wires cables and hoses as shown in the Cable Wire and Hose Routing section of the General Information chapter e Adjust the following Clutch Cable see Engine Right Side chapter Throttle Cable see Fuel System chapter Drive Chain see Final Drive chapter e Fill the engine with coolant see Cooling System chapter e Fill the engine with engine oil see Engine Bottom End Transmission chapter e Adjust the carburetor idling ENGINE BOTTOM END TRANSMISSION 7 1 Engine Bottom End Transmission Exploded View Specifications oooonoooncc c Transmission OU Oil L
171. ter 57001 1415 Type KEK 54 9 B A WARNING Electrical equipment can cause serious electrical shock To avoid being shocked do not touch the metal portion of the probe when measuring voltage If the voltage is less than the specified replace the crank shaft sensor Ignition Coil Removal e Remove the following parts Seat see Frame chapter Fuel Tank see Fuel System chapter e Disconnect the ignition coil primary leads e Pull the plug cap off the spark plug OUnscrew the mounting bolt A and remove the ignition coil B Ignition Coil Installation e Connect the leads according to the Cable Wire and Hose Routing section in the Appendix chapter Ignition Coil Inspection Measuring the arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3 needle method e Remove the ignition coil e Connect the ignition coil with the spark plug cap left in stalled on the spark plug lead A to the tester B and measure the arcing distance A WARNING To avoid extremely high voltage shocks do not touch the coil or lead If the distance reading is less than the specified value the ignition coil or spark plug cap is defective GP100622S1 14 14 ELECTRICAL SYSTEM Ignition System KX85A6F B6F KX100D6F Ignition Coil Arcing Distance Standard 6 mm 0 24 in
172. ter jacket and remove them if necessary e Replace the cylinder base gasket with a new one e Apply engine oil to the piston surface piston rings and cylinder bore e Check to see that the pin A in each piston ring groove is between the ends of the piston ring and fit the base of the cylinder over each ring pressing in on opposite sides of the ring as necessary Be certain that the rings do not slip out of position e Torque Torque Cylinder Nuts 25 N m 2 5 kgf m 18 ft lb e Install the following Carburetor see Fuel System chapter Cylinder Head see Cylinder Head Installation 6E060101S1 ENGINE TOP END 4 7 Cylinder Piston Removal e Remove the cylinder see Cylinder Removal e Stuff a clean cloth into the crankcase opening around the connecting rod so that no parts will fall into the crankcase e Remove one of the piston pin snap rings with needle nose pliers e Remove the piston by pushing the piston pin out the side from which the snap ring was removed Use a piston pin puller assembly A if the pin is tight Special Tools Piston Pin Puller Assembly 57001 910 e Carefully spread the ring A opening with your thumbs and then push up on the opposite side of the ring to re move it Piston Installation e Stuff a clean cloth into the crankcase opening around the connecting rod so that no parts will fall into the crankcase e Scrape off any carbon of the piston then
173. the bearing that is removed from the crankshaft OPosition the crankcase half so that the main bearing hous ing is seated on a suitable press fixture OPress each crankshaft bearing B until it bottoms out us ing a bearing driver A from the driver set which contacts the bearing outer race Special Tool Bearing Driver Set 57001 1129 A Olnstall the crankshaft bearing so that the ball retainer side faces in to the oil seal C side OTurn the crankshaft to BDC and install the crankshaft jig between the crankshaft flywheels to protect fly wheel alignment and press the crankshaft into the right crankcase half Special Tool Crankshaft Jig 57001 1174 e Install the transmission shaft see Transmission Shaft In stallation e Check to see that the crankcase knock pins are in place on the right crankcase half If any of them has been re moved replace it with a new one e Apply liquid gasket to the mating surface of the left crankcase half Sealant Liquid Gasket TB1105B 92104 002 6104016BS1 6104017BS1 ENGINE BOTTOM END TRANSMISSION 7 9 Crankcase e 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 e Using a suitable tool on the left crankcase to press around the hole for the cran
174. the gas reservoir cap must be 1 mm 0 039 in lower than the end C of the gas reservoir A 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 the reservoir with great force and cause serious in jury To avoid injury be sure to install a new circlip in the proper position If the end of the gas reservoir cap is not 1mm lower than the end of the gas reser voir the circlip is not correctly fitted in the groove in the gas reservoir or the circlip is deformed and should be replaced with a new one e Fill the rear shock body and gas reservoir with the spec ified oil and then assemble the rear shock body see Oil Filling Spring Tension Since a spring becomes shorter as it weakens check its free length to determine the condition lf the spring is shorter than the service limit it must be replaced Rear Shock Absorber Spring Free Length Standard 256 mm 10 1 in Service Limit 250 mm 9 8 in Scrapping e Remove the rear shock absorber see Rear Shock Ab sorber Removal e Remove the valve cap and release the nitrogen gas com pletely from the gas reservoir A by pushing down the valve core B with a screwdriver A WARNING The shock contains high pressure nitrogen gas that when suddenly released or is super heated can eject oil and internal shock parts at high veloc ity causing serious injury
175. the tank e Remove the fuel tank and drain it e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Pour the solvent out of the tank e Remove the fuel tap from the tank by taking out the bolts e Clean the fuel tap filter screen in a high flash point sol vent e Pour high flash point solvent through the tap in all lever positions e Dry the tank and tap with compressed air e Install the fuel tap in the tank e Install the fuel tank GCO9072BS1 GCO9094BS1 FUEL SYSTEM 2 19 Reed Valve Removal e Remove the carburetor see Carburetor Removal e Remove the carburetor holder A mounting Bolts and move the rearward e 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 Ib Inspection e Inspect the reeds for cracks folds or other visible dam age x If there is any doubt as to the condition of a reed replace the reed valve part with a new one If a reed becomes wavy replace the valve part with a new one even if its warp is less than the service limit e Measure the clearance between the reed A and holder B and check the reed warp as shown lf any one of the clearance measurements exceeds the service limit replace the valve part with a new one Reed Warp Service Limit 0 2 mm Torque Reed Mountings screws
176. tie rod bolts from the left side e Tighten the tie rod front and rear nuts to the specified torque Torque Tie Rod Nuts 59 N m 6 0 kgf m 44 ft lb Rocker Arm Removal e Raise the rear wheel off the ground see Wheels Tires chapter e Squeeze the brake lever slowly and hold it with a band e Remove the following Tie Rod see Tie Rod Removal Swingarm see Swingarm Removal NOTE O The swingarm may be removed with the rear wheel left installed on it Lower Chain Guide Roller Rocker Arm Bracket Bolts Right and Left A e Remove the rocker arm B Rocker Arm Installation e Apply plenty of molybdenum dislfide grease to the inside of needle bearings and sleeves Rocker Arm Needle Bearings Tie Rod Needle Bearings e Torque Torque Rocker Arm Bracket Bolts 83 N m 8 5 kgf m 61 ft Ib e Install the following Tie Rod see Tie Rod Installation Swingarm see Swingarm Installation SUSPENSION 11 25 Tie Rod Rocker Arm Rocker Arm Tie Rod Bearing Removal e Remove the rocker arm for the rocker arm bearing re moval see Rocker Arm Tie Rod Bearing Removal e Remove the swingarm for the tie rod bearing removal see Rocker Arm Tie Rod Bearing Removal e Remove the grease seal A e Remove the needle bearing Special Tool Bearing Driver Set 57001 1129 e Replace the bearings A and sleeves B with new ones Rocker Arm Tie Rod Bearing Installation e Apply plenty of molybdenum disulfide grease to the
177. ting Section in the General Information chapter Fuel Tap Removal e Remove the fuel tank and drain it e Remove the mounting bolts and take out the fuel tap Fuel Tap Installation e Be sure the O ring is in good condition to prevent leaks e Be sure to clamp the fuel hose to the tap to prevent leaks 2 18 FUEL SYSTEM Fuel Tank Fuel Tap Inspection e Remove the fuel tap e Check the fuel tap filter screen for any breaks or deterio ration x lf the fuel tap screen has any breaks or is deteriorated it may allow dirt to reach the carburetor causing poor run ning Replace the fuel tap x If the fuel tap leaks or allows fuel to flow when it is at OFF position replace the damaged O ring Filter Screen A O rings B KX85A6F B6F KX100D6F C Fuel Tank Cap Inspection e Remove the fuel tank cap e Inspect the gasket on the tank cap for visible damage x Replace the gasket if it is damaged e Remove the breather hose and check to see that the hose is not clogged If it is clogged blow out the breather hose with com pressed air OApply engine oil to the O ring when installing it on the fuel tap Fuel Tank and Tap Cleaning A WARNING Gasoline and low flash point solvents can be flammable and or explosive and cause severe burns Clean the tank in a well ventilated area and take care that there are no sparks or flame any where near the working area Do not use gasoline or low flash point solvents to clean
178. tion e Remove the fuel tank e Remove the carburetor and hold it in true vertical position on a stand e Put the fuel tank on a bench and connect the fuel tap to the carburetor using a suitable hose e Remove the drain plug from the bottom of the float bowl and screw a fuel level gauge A into the plug hole Special Tool Fuel Level Gauge M18 x 1 0 57001 122 e Hold the gauge vertically against the side of the carbure tor body so that the middle line C is several millimeters higher than the float bowl mating surface B e Turn the fuel tap to the ON position to feed fuel to the carburetor e Wait until the fuel level in the gauge settles e Keeping the gauge vertical slowly lower the gauge until the midale line is even with the float bowl mating surface NOTE ODO not lower the zero line below the bottom edge of the carburetor body If the gauge is lowered and then raised again the fuel level measure shows somewhat higher than the actual fuel level If the gauge is lowered too far dump the fuel out of it into a suitable container and start the procedure over again e Read the fuel level D in the gauge and compare it to the specification Service Fuel Level below the float bowl mating surface Standard 1 0 1 mm 0 04 0 04 in e Turn the fuel tap to the OFF position and remove the fuel level gauge x lf the fuel level is incorrect adjust the float height FUEL SYSTEM 2 9 Carburetor
179. tion KX85 A1 A5 B1 B5 KX100 D1 D I 5 16 Primary Gear Removal KX85A6F B6F KX100D6F li 5 16 Primary Gear Installation KX85A6F B6F KX100D6F oococccccoccccccconcccccconanccncannncnnn 5 16 Extetnal Shift Mecha Mon ds 5 18 o A Deeg es 5 18 Install iaa 5 18 INSPOCHO Nica 5 18 Kickstart caia 5 19 A essed ae ices ees Ae ai alee ee ie Pc ae eeu Tad a ace i Se elec Use 5 19 Installation a 5 19 POS SE IMD E 5 19 5 2 ENGINE RIGHT SIDE Exploded View GR02023BW4 C 1 KX85 A1 A5 B1 B5 KX100 D1 D5 T1 9 3 Nm 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 G Apply grease Lh Left hand threads M Apply molybdenum disulfide grease EO Apply engine oil ENGINE RIGHT SIDE 5 3 Exploded View GRO2024BW4 C 1 Idle Gear T6 6 4 N m 0 65 kgf m 56 in lb 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 T2 22 N m 2 2 kgf m 16 ft lb M Apply molybdenum disulfide grease T3 8 8 N m 0 90 kgf m 78 mb ST Staking T4 5 2 N m 0 53 kgf m 46 in lb EO Apply engine oil T5 1 5 Nem 0 15 kgf m 13 in lb 5 4 ENGINE RIGHT SIDE Specifications Item Standard Clutch Lever Free Play 8
180. tment 11 8 SwingArm Bearing Installation 11 23 Fork Oil Change each fork leg 11 8 Swingarm Pivot Inspection 11 23 Front Fork Removal 11 9 Swingarm Bearing Sleeve Front Fork Installation 11 9 e AA 11 23 Disassembly each fork leg 11 10 Tie Rod Rocker ATM 11 24 Assembly each fork leg 11 11 Tie Rod Removal 0005 11 24 Spring Tension cccccceeceeeseeees 11 13 Tie Rod Installation 11 24 Rear Shock Absorber cocccooccccccocncccos 11 14 Rocker Arm Removal 11 24 Compression Damping Force Rocker Arm Installation 11 24 ACJUSIMENT oooominnnerosconerraanoss 11 14 Rocker Arm Tie Rod Bearing Rebound Damping Force Hemova 11 25 et 11 14 Rocker Arm Tie Rod Bearing Preload Adiusiment 11 14 Installation ooccoccccncccccc 11 25 Hemoval oooconcccncconccononincnininininncinns 11 15 Uni Trak Link Pivot Inspection 11 25 Installation 11 16 Rocker Arm Tie Rod Bearing Spring Replacement 00 11 16 Ele A dEr 11 25 Oil AMINO oros 11 17 Rocker Arm Tie Rod Sleeve EI le WE 11 18 INSPOCUON crinii tetris 11 25 11 2 SUSPENSION Exploded View OH D se D COND EL e IMEI Gr om E e QA i med 0600006 OD ce 17 0 comm o EXO ome Eelere JD oo 00 Se GM02170BW4 C tlb tlb tlb tlb q 2 8 kgf m 20 ft 2 0 k
181. to Output Voltage Ignition System Ignition Timing Crankshaft Sensor Air Gap Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage Ignition Coil 3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Ignition Coil Peak Voltage Spark Plug Spark Plug Gap Spark Plug Cap Resistance Magneto Stator Coil Resistance Standard 16 V or more 12 BTDC 12 000 r min rpm KX85A1 A5 B1 B5 12 BTDC 12 040 r min rpm KX85A6F B6F 15 BTDC 12 500 r min rpm KX100D1 D5 21 2 BTDC 10 000 r min rpm KX100D6F 0 4 0 6 mm 0 016 0 024 in 396 594 Q x 100 QO 4 0 V or more 6 mm 0 24 in or more 0 36 0 48 Q x 1 0 5 4 7 4 KQ x 1kQ 110 V or more 0 7 0 8 mm 0 028 0 031 in 3 75 6 25 kQ x 1kQ 288 432 Q x 100 Q Service Limit Special Tools Flywheel Puller M12 x 1 75 57001 252 Hand Tester 57001 1394 Lead Wire Magneto Lead Adapter 57001 1469 Peak Voltage Adapter 57001 1415 Gear Holder 57001 1602 Flywheel amp Pully Holder 57001 1605 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 OThe 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 OTroubles may involve one or i
182. ton pin hole Cylinder Wear Inspection NOTE OMeasure the cylinder inside diameter when the cylinder is cold room or ambient temperature e Inspect the inside of the cylinder for scratches and abnor mal wear x lf the cylinder is damaged or badly worn replace it with a new one e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment shown in the figure lf any of the cylinder inside diameter measurements ex ceeds the service limit the cylinder must be replaced with a new one since the ELECTOR FUSION cylinder cannot be bored or honed 15 mm A 6E060101S1 6E06060281 6E060104S1 ENGINE TOP END 4 9 Cylinder Cylinder Inside Diameter Standard KX85A B 48 505 48 520 mm 1 9096 1 9102 in and less than 0 01 mm 0 0004 in difference between any two measurements KX100D 52 505 52 520 mm 2 0671 2 0677 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit KX85A B 48 60 mm 1 9134 in or more than 0 05 mm 0 0020 in difference between any two measurements KX100D 52 60 mm 2 0709 in or more than 0 05 mm 0 0020 in difference between any two measurements Piston Diameter Measurement e Measure the outside diameter of the piston 17 mm A up from the bottom of the piston at a right angle to the direction of the piston pin If the me
183. uts 25 N m 2 5 kgf m 18 ft lb Spark Plug 26 N m 2 7 kgf m 20 ft Ib e Install the following Muffler see Muffler Installation Radiator see Cooling System chapter Warp Inspection e Lay a straightedge A across the lower surface of the head at several different points and measure warp by inserting a thickness gauge B between the straightedge and the head If warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 03 mm 0 0012 in GEQ50601S1 4 6 ENGINE TOP END Cylinder Cylinder Removal e Drain the coolant see Cooling System chapter Be sure to remove the cylinder drain plug e 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 e Put a spanner wrench A on the shaft lever upper end e Turn the shaft lever clockwise with the wrench and sep arate the link lever B from the link pin e Pull the boot A down e Remove the cylinder nuts B e Lift off the cylinder and remove the cylinder base gasket If necessary tap lightly around the base of the cylinder with a plastic mallet taking care not to damage the cylin der Cylinder Installation e Scrape any carbon out of the exhaust port e Check on acrust of minerals and rust in the cylinder wa
184. ver see Right Engine Cover Removal Clutch Housing Spring Guide A e Pull the end of the kick spring B out of the hole in the crankcase e Remove the ratchet guide C and bolts e Remove the kickstarter assembly D Installation e Apply a thin coat of molybdenum disulfide grease to the kick shaft A journal e Fit the kick shaft assembly in the right crankcase e Set the ratchet guide B as away as possible from the kick shaft and tighten the mounting bolts to the specified torque Torque Ratchet Guide Mounting Bolt 8 8 N m 0 90 kgf m 78 in Ib Ratchet Guide Mounting Screw 5 2 N m 0 53 kgf m 46 in Ib e After installing the assembly turn the kick shaft counter clockwise and check that the shaft returns smoothly with spring force lf the shaft does not return smoothly adjust the ratchet guide position e Install the kick shaft lever as figure GROSOOSBS1 Assembly e Apply molybdenum disulfide grease to the inside of the kick gear and idle gear e Align the notch C on the ratchet A with the hole D on the kick shaft B Misalignment of the ratchet changes the kick spring preload Light preload could cause mech anism noise and heavy preload could weaken or break the spring GR080601S1 ENGINE REMOVAL INSTALLATION 6 1 Engine Removal Installation Table of Contents Exploded E 6 2 Engine Removal Installation ser e2eC Nee See eedee rio 6 3 Sie
185. wiring harness if necessary ELECTRICAL SYSTEM 14 7 Ignition Timing Adjustment e Remove the magneto cover e 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 lf the marks are not aligned loosen the magneto stator mounting screws C and turn the magneto stator D e The ignition timing can be adjusted to change the power band to suit the rider s preference or ability e f necessary adjust the timing by shifting the stator posi tion within the three lines A NOTE OFor best engine performance it is very important to ad just the ignition timing within the adjustable range just explained Crankshaft Rotation A Stator Movement B Retard C Advance D e Tighten the stator mounting screws to the specified torque Torque Stator Mounting Screw 5 2 N m 0 53 kgf m 43 in Ib e Install the magneto cover e Test ride the motorcycle and readjust the ignition timing if necessary 14 8 ELECTRICAL SYSTEM Flywheel Magneto Removal e Remove Magneto Cover e Hold the flywheel steady with the flywheel amp pully holder A and remove the flywheel nut B Special Tool Flywheel amp Pully Holder 57001 1605 e Remove the flywheel holder e Screw the flywheel puller A into the flywheel by turning it counterclockwise left hand thread Special Tool Flywheel Puller M12 x 1 75 57001 252 e Remove the flywheel from the cra
186. x 1 0 57001 1243 57001 1298 T5712438T ST5712988T Bearing Remover Shaft p9 Flywheel Holder 57001 1265 57001 1313 ST571265ST pea c Bearing Remover Head 10 x 12 Fork Oil Seal Driver 36 57001 1266 57001 1352 ST5712668T 1 22 GENERAL INFORMATION Special Tools and Sealants Hand Tester 57001 1394 ST5713948T Fork Cylinder Holder 57001 1413 8757141397 Peak Voltage Adapter 57001 1415 NG Y E Lead Wire Magneto Lead Adapter 57001 1469 ST5714698T Bearing Puller Adapter 57001 1526 ST5715268T Gear Holder 57001 1602 ST5716028T Flywheel amp Pulley Holder 57001 1605 O ST5716058T Liquid Gasket TB1211 56019 120 ST560120ST Liquid Gasket TB1105B 92104 002 ST9200028T GENERAL INFORMATION 1 23 Cable Wire and Hose Routing GB09863CW4 C _ 11 12 13 Run the throttle cable and engine stop button lead through the clamp Do not pinch the throttle cable between the fuel tank and frame Adheve the damper on the frame pipe Run the clutch cable between the clamp and upper and lower radiator installation bolts Radiator Throttle Cable Clutch Cable Engine Stop Button Lead Run the engine stop button lead in front of the bra
187. y KIPS ports clogged carbon accumulation Exhaust valve operating rod seizure Rod for KIPS seized in cylinder Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect C D I Unit trouble Ignition timing maladjusted Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect C D I Unit trouble Ignition timing maladjusted Fuel air mixture incorrect Main jet clogged or wrong size Fuel level in carburetor float bowl too low Carburetor holder loose Air cleaner poorly sealed or missing Air cleaner duct poorly sealed Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Brake dragging Clutch slipping Transmission oil level too high Transmission oil viscosity too high Lubrication inadequate Transmission oil level too low Transmission oil poor quality or incorrect Coolant incorrect Coolant level too low Coolant deteriorated Cooling system component incorrect Radiator clogged Radiator cap trouble Water pump not rotating Water pump impeller damaged Clutch Operation Faulty Clutch slipping No clutch lever play Clutch cable maladjusted Clutch inner cable catching Friction plate worn or warped Steel plate worn or warped 15 4 APPENDIX Troubleshooting Guide Clutch spring broken or weak Clutch release mechanism trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Clutch lever

3 - Vermijs Motorsport

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