Kawasaki KX85, KX85-II & KX100 2013–Present Service Manual (P/N 99924-1470-01)

Kawasaki’s KX85, KX85-II and KX100 service manual covers the KX85CE, KX85DE and KX100FE variants. This is P/N 99924-1470-01, first edition, dated May 17, 2013, with model-identification views and variant-specific engine and chassis specifications.

Searchable Text, Bookmarks and PDF Details

Search and diagram detail: The manual’s body text is searchable, with embedded bookmarks for chapters and individual procedures. Wiring-diagram and ignition-flowchart labels are not searchable; small wire-color codes are readable with zooming.

One printable English PDF contains 332 pages: 8 front-matter pages, 323 chapter and appendix pages, and 1 final model-application page. Nine blank pages are already included in these counts.

Two-Stroke Engine, Chassis and Ignition Service

These selected topics outline the repair coverage. Further sections include silencer-wool replacement and handlebar height and position adjustments.

• Engine top end: Compression testing, piston and cylinder measurement, ring inspection, KIPS exhaust-valve service, and step-by-step engine removal and installation procedures.

• Clutch and transmission: Wet-clutch inspection and assembly, primary-drive and kickstarter service, crankcase separation, crankshaft checks and internal gearbox repair.

• Fuel system: Carburetor fuel-level testing, float adjustment, disassembly and inspection, plus reed-valve and air-cleaner service.

• Cooling system: System pressure testing, radiator-cap inspection, coolant replacement and bleeding, water-pump inspection, and impeller, seal and bearing service.

• Brakes and running gear: Caliper and master-cylinder service, brake bleeding, wheel-bearing replacement, rim checks, chain-wear inspection and sprocket replacement.

• Suspension and steering: Upside-down fork overhaul, rear-shock oil service, Uni-Trak linkage inspection, steering-stem bearing replacement and damping adjustments.

• Ignition diagnosis: Wiring diagram, magneto output tests, crankshaft-sensor checks, ignition-coil testing and a fault-tracing flowchart.

Written primarily for trained mechanics in an equipped shop, the manual also supports owners doing basic maintenance and repair who understand mechanical work, tools and workshop procedures.

Engine Inspection, Assembly and Special Tools

This factory publication breaks down the teardown, inspection, and assembly of the 2-stroke single-cylinder powerplants. Its compression-diagnosis table connects abnormal readings with piston/ring wear, gasket leakage and crankcase sealing faults, helping narrow the checks needed before internal repair.

Cylinder and crankshaft work: The inspection sections give separate piston and bore limits for the engine variants. Plated cylinders are not suitable for boring or honing. Crankshaft disassembly and reassembly require a shop with the necessary equipment; clearance, runout and alignment checks are included.

Tool references include Crankcase Splitting Tool Assembly 57001-1098 and Crankshaft Jig 57001-1174. Assembly notes explain how reused piston-pin snap rings can score the cylinder wall and why replacement crankcase halves must be supplied as a matched set.

Carburetor Setup and Cooling Checks

Model-specific jet-needle, clip-position and air-screw settings accompany fuel-level and float-height measurements. Carburetor exploded views identify the jets and throttle components, while inspection procedures address float-valve and needle wear.

Radiator-cap relief-pressure specifications are separate from the cooling-system leak test. Water-pump seal and bearing work is cross-referenced to the right-engine-cover procedures.

Chassis, Suspension and Brake Service

Chassis variants: The KX85CE uses smaller wheels than KX85DE and KX100FE; the latter share chassis dimensions and final-drive gearing.

Front-fork coverage extends to the compression-valve assembly, cylinder unit, bushings and seals. Rear-shock instructions include bladder inspection, oil filling and nitrogen charging; the manual assigns reservoir pressurization to a qualified mechanic because of the high-pressure gas hazard.

The brake sections distinguish front and rear assemblies and include seal-condition checks and checks for braking power, drag and leakage after service. Maintenance schedules cover the engine, cooling and final drive, with torque/locking-agent tables and component wear limits.

Ignition Fault Tracing and Assembly Illustrations

The Wiring Diagram maps the CDI unit, magneto, crankshaft sensor and engine-stop circuit. The ignition Troubleshooting flowchart separates low peak voltage from faults that remain despite a normal reading. Coil resistance testing is qualified by its inability to reveal every high-voltage insulation fault.

Cable, Wire, and Hose Routing views, Engine Right Side exploded views and transmission-shaft assembly illustrations support component identification and reassembly. Appendix troubleshooting also covers starting, poor running, shifting and handling complaints.

Selected Jetting, Fastener and Spark Plug Specifications

Carburetor specifications list a #140 main jet, with NRJC jet needles for KX85C/D and NRKC for KX100F. The table also gives clip-position and air-screw settings.

Fastener data specifies 25 N·m for the cylinder-head nuts and 78 N·m for both axle nuts. The standard NGK R6252K-105 spark plug has a 0.7–0.8 mm gap; the electrical specifications distinguish the optional plug and its gap.